CA2077033A1 - Polypropylene resin composition - Google Patents
Polypropylene resin compositionInfo
- Publication number
- CA2077033A1 CA2077033A1 CA002077033A CA2077033A CA2077033A1 CA 2077033 A1 CA2077033 A1 CA 2077033A1 CA 002077033 A CA002077033 A CA 002077033A CA 2077033 A CA2077033 A CA 2077033A CA 2077033 A1 CA2077033 A1 CA 2077033A1
- Authority
- CA
- Canada
- Prior art keywords
- weight
- ethylene
- component
- copolymer
- polypropylene
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
Links
Classifications
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
- C08K3/00—Use of inorganic substances as compounding ingredients
- C08K3/34—Silicon-containing compounds
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L53/00—Compositions of block copolymers containing at least one sequence of a polymer obtained by reactions only involving carbon-to-carbon unsaturated bonds; Compositions of derivatives of such polymers
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L2205/00—Polymer mixtures characterised by other features
- C08L2205/02—Polymer mixtures characterised by other features containing two or more polymers of the same C08L -group
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L23/00—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers
- C08L23/02—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers not modified by chemical after-treatment
- C08L23/04—Homopolymers or copolymers of ethene
- C08L23/08—Copolymers of ethene
- C08L23/0807—Copolymers of ethene with unsaturated hydrocarbons only containing more than three carbon atoms
- C08L23/0815—Copolymers of ethene with aliphatic 1-olefins
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L23/00—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers
- C08L23/02—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers not modified by chemical after-treatment
- C08L23/16—Elastomeric ethene-propene or ethene-propene-diene copolymers, e.g. EPR and EPDM rubbers
Abstract
POLYPROPYLENE RESIN COMPOSITION
ABSTRACT OF THE DISCLOSURE
A polypropylene resin composition comprising:
(A) 45 to 70% by weight of an ethylene-propylene block copolymer synthesized under the process comprising the steps of;
(a) polymerizing propylene with a Ziegler-Natta catalyst to obtain a highly crystalline polypropylene that contain not less than 97% by weight of a fraction insoluble in boiling n-heptane, and (b) copolymerizing ethylene with the polypropylene (a), and which (a) contains 0.5 to 10% by weight of ethylene, (b) contains 5 to 20% by weight of a fraction being soluble in p-xylene at room temperature and having an intrinsic viscosity value of not less than 2 (measured in decalin at 135°C), (c) has a melt-flow index value of 30 to 100g/10 min., and, (d) has a value of flexure modulus of not less than 18,000 kg/cm2, (B) 10 to 20% by weight of an amorphous ethylene-propylene copolymer having (a) an ethylene content of 70 to 90% by weight, (b) a Mooney viscosity value (ML1+4 at 100°C) of 5 to 20, (C) 5 to 15% by weight of an ethylene-.alpha.-olefin copolymer having (a) an .alpha.-olefin content of 5 to 15% by mole, (b) a value of gravity of not more than 0.91, and (c) a melt-flow index value of 2.2 to 50 g/10 min. at 230°C, (D) 1 to 10% by weight of an amorphous ethylene-butene copolymer having (a) a butene content of 10 to 25% by weight, and (b) a Mooney viscosity value (ML1+4, at 100°C) of 5 to 20, (E) not more than 15% by weight of a talc that (a) has an average diameter D50 of from 1.0 to 3.0 µm, and (b) does not contain a particle having a diameter of 10 µm or more, wherein the component (B) is rubber reinforced by lamellae of components (C) and (D).
ABSTRACT OF THE DISCLOSURE
A polypropylene resin composition comprising:
(A) 45 to 70% by weight of an ethylene-propylene block copolymer synthesized under the process comprising the steps of;
(a) polymerizing propylene with a Ziegler-Natta catalyst to obtain a highly crystalline polypropylene that contain not less than 97% by weight of a fraction insoluble in boiling n-heptane, and (b) copolymerizing ethylene with the polypropylene (a), and which (a) contains 0.5 to 10% by weight of ethylene, (b) contains 5 to 20% by weight of a fraction being soluble in p-xylene at room temperature and having an intrinsic viscosity value of not less than 2 (measured in decalin at 135°C), (c) has a melt-flow index value of 30 to 100g/10 min., and, (d) has a value of flexure modulus of not less than 18,000 kg/cm2, (B) 10 to 20% by weight of an amorphous ethylene-propylene copolymer having (a) an ethylene content of 70 to 90% by weight, (b) a Mooney viscosity value (ML1+4 at 100°C) of 5 to 20, (C) 5 to 15% by weight of an ethylene-.alpha.-olefin copolymer having (a) an .alpha.-olefin content of 5 to 15% by mole, (b) a value of gravity of not more than 0.91, and (c) a melt-flow index value of 2.2 to 50 g/10 min. at 230°C, (D) 1 to 10% by weight of an amorphous ethylene-butene copolymer having (a) a butene content of 10 to 25% by weight, and (b) a Mooney viscosity value (ML1+4, at 100°C) of 5 to 20, (E) not more than 15% by weight of a talc that (a) has an average diameter D50 of from 1.0 to 3.0 µm, and (b) does not contain a particle having a diameter of 10 µm or more, wherein the component (B) is rubber reinforced by lamellae of components (C) and (D).
Description
~ ~3 us-9450-c~
POLYPROPYLENE RESIN COMPOSITION
BACKGROUND OF THE INVENTION
1. Field of the Invention This invention relates to a polypropylene resin composition. More specifically, it relates to a polypropylene composition suitable for a large molding such as an automobile bumper.
POLYPROPYLENE RESIN COMPOSITION
BACKGROUND OF THE INVENTION
1. Field of the Invention This invention relates to a polypropylene resin composition. More specifically, it relates to a polypropylene composition suitable for a large molding such as an automobile bumper.
2. Description of the Related Art A polypropylene resin has often been used when molding such products as automobile bumpers because it is light, corrosion-proof, and intricately shaped products such as automobile bumpers can be easily molded from said resin.
Although a polypropylene resin is thought to be suitable for an automobile bumper, an automobile bumper made of a polypropylene resin does not have enough impact strength, and does not paint well. Recently, a polypropylene resin composition composed of a polypropylene polymer, an ethylene-propylene rubber, and an inorganic filler was used for an automobile bumper to impro~e the impact strength and paintability of the bumper. Japanese Unexamined Patent Publication (Xokai) No. 55-21494 discloses a composition of polyolefin such as an isotactic polypropylene, high density pol~ethylene, low density polyethylene, or ethylene-propylene copolymer, an elastomer such as ethylene-propylene rubber or ethylene propylene-diene terpolymer, and an inorganic filler. Japanese Kokai Nos. 57-55952 and 58-111846 disclose a composition of a crystalline ethylene~
propylene block copolymer, an amorphous ethylene propylene copolymer, and a talc. Japanese Kokai No. 57-159841 discloses a composition of a crystalline ethylene-propylene block copolymer, an amorphous ethylene-propylene copolymer, a high density polyethylene, and a talc. Japanese Kokai No. 57-19S134 discloses a composition of a polypropylene polymer, an elastomer, a compound selected from aromatic sulfonic acid, an aromatic carboxylic acid, a C4 to Cl2 aliphatic dicarboxylic acid, an aromatic phosphine, a metallic salt of the aromatic phosphine, and a dibenzylidene sorbitol, and an inorganic filler. Japanese Kokai Nos. 57-207630 and 58-17139 disclose a composition of a crystalline polyolefin, an ethylene~~-olefin rubber, and an inorganic filler selected from talc, mica, and calcium silicate.
An automobile bumper molded from these compositions, although improved in impact strength, has a poor appearance, poor surface hardness, and poor paintability (i.e. paint coated on the automobile bumper is easily scratched off).
SUM~RY OF THE INVENTION
Accordingly, the object of this invention is to provide a polypropylene resin composition capable of producing an automobile bumper that has high impact strength, good appearance, high surface hardn0ss, and excellent paintability.
In accordance with this invention, there is provided a polypropylene resin composition comprising:
(A) 45 to 70% by weight of a crystalline ethylene-propylene block copolymer, (B) 10 to 20% by weight of an amorphous ethylene-propylene copolymer, (C) 5 to 15% by weight of an ethylene-~-olefin copolymer, (D) 1 to 10% by weight of an amorphous ethylene-butene copolymer, and (E) not more than 15% by weight of a talc.
In this invention, the component (B) mentioned above is reinforced by components (C) and (D) lamellae. In a polypropylene resin composition according to this invention, component (A) functions to make the composition flow well in a mold during molding and provide rigidity to the molding obtained, component (B) functions to provide impact strength to the molding obtained, component (C) is an ultra low density polyethylene and is dispersed as lamellae in the particles of component (B) to reinforce the same, and component (D) functions as an agent to make component (B) compatible with component (C).
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will be better understood from the description set forth below with reference to the accompanying drawings wherein:
Figure 1 is an electric microscope photograph (x 5,000) o~ a cross section of an automobile bumper molded from the polypropylene resin of Example 4, Fig. 2 is an electric microscope photograph (x 100,000) of a cross section of the same automobile bumper of Fig. 1, Fig. 3 is an electric microscope photograph (x 5,000) of a cross section of an automobile bumper molded from the polypropylene resin of Comparative Example 3, Fig. 4 is an electric microscope photograph (x 100,000) of a cross section of the same automobile bumper of Fig. 3.
In Figs. 1 to 4, the dark gray areas are elastomeric component (components (B), (C) and (D) of this invention) domains and the light gray areas are crystalline ethylene-propylene copolymer component (component (A) of this invention) domains.
Comparing Fig. 1 with Fig. 3, it is apparent that a polypropylene resin composition of this invention has a structure quite different from that of an ordinary polypropylene resin composition. Although elastomeric components disperse insularly in the compositions of Figs. 1 and 3, the elastomeric components of Fig. 1 disperse as flattened particles and the boundaries between elastomeric component domains and ethylene-propylene copolymer domains are unclear.
2~7~
Fig. 2 shows that medium gray lamellae disperse in a dark gray area. The medium gray lamellae are lamellae of components (C) and (D). The dark gray area is a particle of component (B). This shows that components (C) and (D) disperses as lamellae in the particles of component (B).
DESCRIPTION OF THE PREFERRED EMBODIMENT
In this invention, component (A) is a highly crystalline ethylene-propylene block copolymer synthesized under the process comprising the steps of;
(a) polymerizing propylene with a Ziegler-Natta catalyst to obtain a highly crystalline polypropylene that contains not less than 97% by weight, preferably not less than 97.5% by weight of a fraction insoluble in boiling n-heptane, and ~b) copolymerizing ethylene with the polypropylene (a).
This ethylene-propylene block copolymer mainly consists of a polypropylene fragment and an ethylene-propylene copolymer fragment. The polypropylene fragment is formed in the first step, the amorphous ethylene-propylene copolymer fragment is formed in the second step.
Component (A) should contain 0.5 to 10% by weight, preferably 1.5 to 7% by weight of ethylene, and 5 to 20%
by weight, preferably 6 to 15% by weight of a fraction soluble in p-xylene at room temperature and having an intrinsic viscosi-ty of 2 or more, preferably 3 to 12, measured in decalin at 135C. In addition, component (A) should have a melt-flow index value of 30 to 100 g/10 min., preferably 40 to 80 g/10 min., and a flexural modulus value of not less than 18,000 kg/cm2, preferably 19,000 to 25,000 kg/cm2.
When using a polypropylene which contains less than 97% by weight of a fraction insoluble in a boiling n-heptane to obtain component (A), a molding having insufficient surface hardness is obtained.
- 5 ~
When an ethylene-propylene block copolymer which contains less than 0.5% by weight of ethylene is employed as component (A), a molding having sufficient impact strength cannot be obtained. On the other hand, when an ethylene-propylene block copolymer which contains more than 10~ by weight of ethylene, a molding having sufficient surface hardness cannot be obtained.
When using a block copolymer having an intrinsic viscosity value of less than 2 (at 135C, in decalin) as component (A), a molding having insufficient Izod impac~
strength at -30C is obtained.
When using a block copolymer containing less than 5%
by weight of a fraction soluble in p-xylene at room temperature as component (A), a molding having insufficient impact strength is obtained. On the other hand, when a block copolymer containing more than 20% by weight is employed, a molding having insufficient rigidity is obtained.
When using a block copolymer having a melt flow index value of less than 30 g/10 min. as component (A), a polypropylene resin composition does not flow well in a mold and a molding having a poor appearance is obtained.
On the other hand, when employing a block copolymer having a melt flow index value of more than 100 g/10 min.
as component (A), a molding having insufficient impact strength is obtained.
When employing a block copolymer having a value of a flexural modulus of less than 18,000 kg/cm2, a molding having insufficient rigidity and insufficient surface hardness is obtained.
Component (B) according to this invention is an amorphous ethylene-propylene copolymer i.e., an ethylene propylene rubber. Component (B) should contain 70 to 90%
by weight, preferably 72 to 85% by weight of ethylene and has a Mooney viscosity value (MLl.~4 at 100C) of 5 to 70, preferably 10 to 60.
- 6 _ ~r~
When employing an amorphous ethylene-propylene copolymer which contains less than 70% by weight of ethylene as component (B), a molding having insufficient surface hardness is obtained. On the other hand, when employing an amorphous ethylene-propylene copolymer which contains more than 90% by weight of ethylene as component (B), a molding having insufficient impact strength is obtained.
An amorphous ethylene-propylene copolymer having a ~ooney viscosity value of less than 5 is not suitable for component (B), because such a copolymer has too a small molecular weight and the molding obtained is insufficient in impact strength. An amorphous ethylene-propylene copolymer having a Mooney viscosity value of more than 70 is not suitable, too, because such a copolymer has too large a molecular weight and it is hard to disperse such a copolymer into component (A).
Component (C) is an ethylene-~-olefin copolymer which is called an ultra low density polyethylene. In this invention, a copolymer of ethylene and an ~-olefin having 4 to 10 carbon atoms can be employed as component (C). Ethylene-butene-1 copolymer, ethylene-butene-1 copolymer, ethylene-4-methylpentene-1 copolymer, ethylene-1-hexene copolymer, and ethylene-1-octene copolymer are preferably employed in this invention.
Especially, ethylene-butene-l copolymer and ethylene-4-methylpentene-l copolymer are preferable.
Component (C) should have an a-olefin content of from 5 to 15% by mole, preferably 7 to 15% by mole and have a gravity of 0.91 or less. Component (C) should have a melt flow index value at 230C of from 2.2 to 50 g/10 min., preferably 6 to 40 g/10 min.
When employing an ethylene-~-olefin copolymer containing less than 5% by mole of an ~-olefin as component (C), lamellae of component (C) reinforces component (B) excessively and thereby reducing the impact strength of the molding obtained. On the other hand, - 7 - ~ 3~
when employing an ethylene-~-olefin copolymer containing more than 15% by mole of an a-olefin as component (C), component (B) is not sufficiently xeinforced by component (C) and the molding is obtained insufficient in surface hardness and flexural modulus.
When a gravity value of component (C) is more than 0.91, a molding insufficient in impact strength is obtained.
Component (D) is an amorphous ethylene-butene copolymer having a butene content of 10 to 25% by weight and a Mooney viscosity value (ML1~4r at 100C) of 5 to 20.
When employing an amorphous ethylene-butene copolymer having a butene content of less than 10% by weight or an amorphous ethylene-butene copolymer having a Mooney viscosity value of less than 5 as component (D), a molding insufficient in impact strength is obtained. On the other hand, when employing an amorphous ethylene-butene copolymer having a butene content o~ more than 25%
by weight, a molding that is too soft is obtained.
Compound (E) is a talc having an average diameter of 1.0 to 3.0 ~m, preferably having 1.0 to 2.5 ~m and not containing a fraction having a diameter of more than 10 ~m.
When employing a talc having an average diameter of less than 1 ~m, it is difficult to disperse the talc. On the other hand, when employing a talc having an average diameter of more than 3 ~m, the molding obtained is too rigid.
A talc treated with a surface treatment agent can be employed as component (E) in this invention. As a surface treatment agent, a silan coupling agent, an aliphatic acid, a metal carboxylate, an unsaturated carboxylic acid, an unsaturated carboxylic acid derivative, an organic titanate, a resin acid, a metallic resinate, and a polyethylene glycol ether can be included.
- 8 - ~ 3~
The amount of component (A) should be 45 to 70% by weight, preferably 50 to 60% by weight. When the amount of component (A) is less than 45% by weight, the polypropylene resin composition does not flow well in a mold during molding and a molding with a good appearance cannot be obtained. On khe other hand, when the amount of the component (A) exceeds 70% by weight, a molding having poor paintability, i.e., paint coated on the molding is easily scratched off, is obtained.
The amount of component (B) should be 10 to 20% by weight, preferably 12 to 20% by weight. When the amount of component (B) is less than 10% by weight, a molding having insufficient impact strength and poor paintability is obtained. On the other hand, when the amount of the lS componen~ (B) exceeds 20% by weight, a molding insufficient in rigidity is obtained.
The amount of component (C) should be 5 to 15% by weight, preferably 8 to 15% by weight. When the amount of component (C) is less than 5% by weight, a molding obtained from this polypropylene resin composition has insufficient impact strength. On the other hand, when the amount of the component (C) exceeds 15% by weight, a molding having insufficient rigidity is obtained.
The amount of component (D) should be 1 to 10% by weight, preferably 1 to 5% by weight. When a polypropylene resin composition contains less than 1% by weight, or more than 10% by weight, of component tD), a molding obtained from the composition is insufficient in rigidity and impact strength.
The amount of component (E) should be 15% by weight or less, preferably 8 to 15% by weight, more preferably 10 to 15% by weight. When a polypropylene resin composition contains more than 15% by weight of component (E), a molding obtained from the composition is sufficient in impact strength.
The polypropylene resin composition of khis invention may contain any conventional ingredients such as pigments, antioxidants, ultraviolet absorbents, and lubricants, unless the desired properties thereof are not adversely effected.
The polypropylene resin composition of this invention can be prepared by mixing the above-mentioned melted components with an apparatus such as a V-type blender, a single- or twin-screw extruder, a Banbury mixer, a continuous mixer, or a mixing roll. All of the components can be mixed at the same time to prepare a polypropylene resin composition of this invention. This polypropylene resin composition can be prepared by another process, e.g., mixing component (A) and (E) at first, then, mixing components (B), (C), and (D) to the mixture of components (A) and (E).
EXAMPLES
This invention will be further illustrated in detail by, but by no means limited to, the following Examples < wherein "parts" are all by weight unless otherwise noted.
Examples l to 10 and ComParative Examples 1 to 18 Component (~) to (E) were blended according to the recipe shown in Table 1. A 0.1 part amount of 2,6-di-tertiary butyl-4-methylphenol and 0.3 parts of pentaerithrityl-tetrakis[3-(3,5-di-tertiary butyl-4-hydroxyphenyl)propionate (i.e., both of them are antioxidant), 0.3 parts of bis(2,2,6,6-tetramethyl-4-piperidyl) sebacate (i.e., ultraviolet absorbent), 0.2 parts of magnesium stearate and 0.2 parts of magnesium stearate (i.e., both of them are lubricant) and 1.0 part of carbon black were added to the polypropylene resin composition. All of the components and additives were mixed with a tumbler, then, the mixture was melted and blended with a twin-screw extruder at 220C to obtain polypropylene resin compositions. The polypropylene resin composi.tions thus obtained were molded into test pieces with an injection molding machine under the conditions mentioned below;
- 1 o - 2~
(1) Injection molding machine; UBE MAX D150-10 (2) Shape of test piece;
rectangular, size: 36~ mm x 140 mm x 3 mm (test pieces for appearance measurement) rectangular, size: 50 mm x 90 mm x 2 mm (test pieces for painta~ility measurement) (3) Injection temperature; 220C
Although a polypropylene resin is thought to be suitable for an automobile bumper, an automobile bumper made of a polypropylene resin does not have enough impact strength, and does not paint well. Recently, a polypropylene resin composition composed of a polypropylene polymer, an ethylene-propylene rubber, and an inorganic filler was used for an automobile bumper to impro~e the impact strength and paintability of the bumper. Japanese Unexamined Patent Publication (Xokai) No. 55-21494 discloses a composition of polyolefin such as an isotactic polypropylene, high density pol~ethylene, low density polyethylene, or ethylene-propylene copolymer, an elastomer such as ethylene-propylene rubber or ethylene propylene-diene terpolymer, and an inorganic filler. Japanese Kokai Nos. 57-55952 and 58-111846 disclose a composition of a crystalline ethylene~
propylene block copolymer, an amorphous ethylene propylene copolymer, and a talc. Japanese Kokai No. 57-159841 discloses a composition of a crystalline ethylene-propylene block copolymer, an amorphous ethylene-propylene copolymer, a high density polyethylene, and a talc. Japanese Kokai No. 57-19S134 discloses a composition of a polypropylene polymer, an elastomer, a compound selected from aromatic sulfonic acid, an aromatic carboxylic acid, a C4 to Cl2 aliphatic dicarboxylic acid, an aromatic phosphine, a metallic salt of the aromatic phosphine, and a dibenzylidene sorbitol, and an inorganic filler. Japanese Kokai Nos. 57-207630 and 58-17139 disclose a composition of a crystalline polyolefin, an ethylene~~-olefin rubber, and an inorganic filler selected from talc, mica, and calcium silicate.
An automobile bumper molded from these compositions, although improved in impact strength, has a poor appearance, poor surface hardness, and poor paintability (i.e. paint coated on the automobile bumper is easily scratched off).
SUM~RY OF THE INVENTION
Accordingly, the object of this invention is to provide a polypropylene resin composition capable of producing an automobile bumper that has high impact strength, good appearance, high surface hardn0ss, and excellent paintability.
In accordance with this invention, there is provided a polypropylene resin composition comprising:
(A) 45 to 70% by weight of a crystalline ethylene-propylene block copolymer, (B) 10 to 20% by weight of an amorphous ethylene-propylene copolymer, (C) 5 to 15% by weight of an ethylene-~-olefin copolymer, (D) 1 to 10% by weight of an amorphous ethylene-butene copolymer, and (E) not more than 15% by weight of a talc.
In this invention, the component (B) mentioned above is reinforced by components (C) and (D) lamellae. In a polypropylene resin composition according to this invention, component (A) functions to make the composition flow well in a mold during molding and provide rigidity to the molding obtained, component (B) functions to provide impact strength to the molding obtained, component (C) is an ultra low density polyethylene and is dispersed as lamellae in the particles of component (B) to reinforce the same, and component (D) functions as an agent to make component (B) compatible with component (C).
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will be better understood from the description set forth below with reference to the accompanying drawings wherein:
Figure 1 is an electric microscope photograph (x 5,000) o~ a cross section of an automobile bumper molded from the polypropylene resin of Example 4, Fig. 2 is an electric microscope photograph (x 100,000) of a cross section of the same automobile bumper of Fig. 1, Fig. 3 is an electric microscope photograph (x 5,000) of a cross section of an automobile bumper molded from the polypropylene resin of Comparative Example 3, Fig. 4 is an electric microscope photograph (x 100,000) of a cross section of the same automobile bumper of Fig. 3.
In Figs. 1 to 4, the dark gray areas are elastomeric component (components (B), (C) and (D) of this invention) domains and the light gray areas are crystalline ethylene-propylene copolymer component (component (A) of this invention) domains.
Comparing Fig. 1 with Fig. 3, it is apparent that a polypropylene resin composition of this invention has a structure quite different from that of an ordinary polypropylene resin composition. Although elastomeric components disperse insularly in the compositions of Figs. 1 and 3, the elastomeric components of Fig. 1 disperse as flattened particles and the boundaries between elastomeric component domains and ethylene-propylene copolymer domains are unclear.
2~7~
Fig. 2 shows that medium gray lamellae disperse in a dark gray area. The medium gray lamellae are lamellae of components (C) and (D). The dark gray area is a particle of component (B). This shows that components (C) and (D) disperses as lamellae in the particles of component (B).
DESCRIPTION OF THE PREFERRED EMBODIMENT
In this invention, component (A) is a highly crystalline ethylene-propylene block copolymer synthesized under the process comprising the steps of;
(a) polymerizing propylene with a Ziegler-Natta catalyst to obtain a highly crystalline polypropylene that contains not less than 97% by weight, preferably not less than 97.5% by weight of a fraction insoluble in boiling n-heptane, and ~b) copolymerizing ethylene with the polypropylene (a).
This ethylene-propylene block copolymer mainly consists of a polypropylene fragment and an ethylene-propylene copolymer fragment. The polypropylene fragment is formed in the first step, the amorphous ethylene-propylene copolymer fragment is formed in the second step.
Component (A) should contain 0.5 to 10% by weight, preferably 1.5 to 7% by weight of ethylene, and 5 to 20%
by weight, preferably 6 to 15% by weight of a fraction soluble in p-xylene at room temperature and having an intrinsic viscosi-ty of 2 or more, preferably 3 to 12, measured in decalin at 135C. In addition, component (A) should have a melt-flow index value of 30 to 100 g/10 min., preferably 40 to 80 g/10 min., and a flexural modulus value of not less than 18,000 kg/cm2, preferably 19,000 to 25,000 kg/cm2.
When using a polypropylene which contains less than 97% by weight of a fraction insoluble in a boiling n-heptane to obtain component (A), a molding having insufficient surface hardness is obtained.
- 5 ~
When an ethylene-propylene block copolymer which contains less than 0.5% by weight of ethylene is employed as component (A), a molding having sufficient impact strength cannot be obtained. On the other hand, when an ethylene-propylene block copolymer which contains more than 10~ by weight of ethylene, a molding having sufficient surface hardness cannot be obtained.
When using a block copolymer having an intrinsic viscosity value of less than 2 (at 135C, in decalin) as component (A), a molding having insufficient Izod impac~
strength at -30C is obtained.
When using a block copolymer containing less than 5%
by weight of a fraction soluble in p-xylene at room temperature as component (A), a molding having insufficient impact strength is obtained. On the other hand, when a block copolymer containing more than 20% by weight is employed, a molding having insufficient rigidity is obtained.
When using a block copolymer having a melt flow index value of less than 30 g/10 min. as component (A), a polypropylene resin composition does not flow well in a mold and a molding having a poor appearance is obtained.
On the other hand, when employing a block copolymer having a melt flow index value of more than 100 g/10 min.
as component (A), a molding having insufficient impact strength is obtained.
When employing a block copolymer having a value of a flexural modulus of less than 18,000 kg/cm2, a molding having insufficient rigidity and insufficient surface hardness is obtained.
Component (B) according to this invention is an amorphous ethylene-propylene copolymer i.e., an ethylene propylene rubber. Component (B) should contain 70 to 90%
by weight, preferably 72 to 85% by weight of ethylene and has a Mooney viscosity value (MLl.~4 at 100C) of 5 to 70, preferably 10 to 60.
- 6 _ ~r~
When employing an amorphous ethylene-propylene copolymer which contains less than 70% by weight of ethylene as component (B), a molding having insufficient surface hardness is obtained. On the other hand, when employing an amorphous ethylene-propylene copolymer which contains more than 90% by weight of ethylene as component (B), a molding having insufficient impact strength is obtained.
An amorphous ethylene-propylene copolymer having a ~ooney viscosity value of less than 5 is not suitable for component (B), because such a copolymer has too a small molecular weight and the molding obtained is insufficient in impact strength. An amorphous ethylene-propylene copolymer having a Mooney viscosity value of more than 70 is not suitable, too, because such a copolymer has too large a molecular weight and it is hard to disperse such a copolymer into component (A).
Component (C) is an ethylene-~-olefin copolymer which is called an ultra low density polyethylene. In this invention, a copolymer of ethylene and an ~-olefin having 4 to 10 carbon atoms can be employed as component (C). Ethylene-butene-1 copolymer, ethylene-butene-1 copolymer, ethylene-4-methylpentene-1 copolymer, ethylene-1-hexene copolymer, and ethylene-1-octene copolymer are preferably employed in this invention.
Especially, ethylene-butene-l copolymer and ethylene-4-methylpentene-l copolymer are preferable.
Component (C) should have an a-olefin content of from 5 to 15% by mole, preferably 7 to 15% by mole and have a gravity of 0.91 or less. Component (C) should have a melt flow index value at 230C of from 2.2 to 50 g/10 min., preferably 6 to 40 g/10 min.
When employing an ethylene-~-olefin copolymer containing less than 5% by mole of an ~-olefin as component (C), lamellae of component (C) reinforces component (B) excessively and thereby reducing the impact strength of the molding obtained. On the other hand, - 7 - ~ 3~
when employing an ethylene-~-olefin copolymer containing more than 15% by mole of an a-olefin as component (C), component (B) is not sufficiently xeinforced by component (C) and the molding is obtained insufficient in surface hardness and flexural modulus.
When a gravity value of component (C) is more than 0.91, a molding insufficient in impact strength is obtained.
Component (D) is an amorphous ethylene-butene copolymer having a butene content of 10 to 25% by weight and a Mooney viscosity value (ML1~4r at 100C) of 5 to 20.
When employing an amorphous ethylene-butene copolymer having a butene content of less than 10% by weight or an amorphous ethylene-butene copolymer having a Mooney viscosity value of less than 5 as component (D), a molding insufficient in impact strength is obtained. On the other hand, when employing an amorphous ethylene-butene copolymer having a butene content o~ more than 25%
by weight, a molding that is too soft is obtained.
Compound (E) is a talc having an average diameter of 1.0 to 3.0 ~m, preferably having 1.0 to 2.5 ~m and not containing a fraction having a diameter of more than 10 ~m.
When employing a talc having an average diameter of less than 1 ~m, it is difficult to disperse the talc. On the other hand, when employing a talc having an average diameter of more than 3 ~m, the molding obtained is too rigid.
A talc treated with a surface treatment agent can be employed as component (E) in this invention. As a surface treatment agent, a silan coupling agent, an aliphatic acid, a metal carboxylate, an unsaturated carboxylic acid, an unsaturated carboxylic acid derivative, an organic titanate, a resin acid, a metallic resinate, and a polyethylene glycol ether can be included.
- 8 - ~ 3~
The amount of component (A) should be 45 to 70% by weight, preferably 50 to 60% by weight. When the amount of component (A) is less than 45% by weight, the polypropylene resin composition does not flow well in a mold during molding and a molding with a good appearance cannot be obtained. On khe other hand, when the amount of the component (A) exceeds 70% by weight, a molding having poor paintability, i.e., paint coated on the molding is easily scratched off, is obtained.
The amount of component (B) should be 10 to 20% by weight, preferably 12 to 20% by weight. When the amount of component (B) is less than 10% by weight, a molding having insufficient impact strength and poor paintability is obtained. On the other hand, when the amount of the lS componen~ (B) exceeds 20% by weight, a molding insufficient in rigidity is obtained.
The amount of component (C) should be 5 to 15% by weight, preferably 8 to 15% by weight. When the amount of component (C) is less than 5% by weight, a molding obtained from this polypropylene resin composition has insufficient impact strength. On the other hand, when the amount of the component (C) exceeds 15% by weight, a molding having insufficient rigidity is obtained.
The amount of component (D) should be 1 to 10% by weight, preferably 1 to 5% by weight. When a polypropylene resin composition contains less than 1% by weight, or more than 10% by weight, of component tD), a molding obtained from the composition is insufficient in rigidity and impact strength.
The amount of component (E) should be 15% by weight or less, preferably 8 to 15% by weight, more preferably 10 to 15% by weight. When a polypropylene resin composition contains more than 15% by weight of component (E), a molding obtained from the composition is sufficient in impact strength.
The polypropylene resin composition of khis invention may contain any conventional ingredients such as pigments, antioxidants, ultraviolet absorbents, and lubricants, unless the desired properties thereof are not adversely effected.
The polypropylene resin composition of this invention can be prepared by mixing the above-mentioned melted components with an apparatus such as a V-type blender, a single- or twin-screw extruder, a Banbury mixer, a continuous mixer, or a mixing roll. All of the components can be mixed at the same time to prepare a polypropylene resin composition of this invention. This polypropylene resin composition can be prepared by another process, e.g., mixing component (A) and (E) at first, then, mixing components (B), (C), and (D) to the mixture of components (A) and (E).
EXAMPLES
This invention will be further illustrated in detail by, but by no means limited to, the following Examples < wherein "parts" are all by weight unless otherwise noted.
Examples l to 10 and ComParative Examples 1 to 18 Component (~) to (E) were blended according to the recipe shown in Table 1. A 0.1 part amount of 2,6-di-tertiary butyl-4-methylphenol and 0.3 parts of pentaerithrityl-tetrakis[3-(3,5-di-tertiary butyl-4-hydroxyphenyl)propionate (i.e., both of them are antioxidant), 0.3 parts of bis(2,2,6,6-tetramethyl-4-piperidyl) sebacate (i.e., ultraviolet absorbent), 0.2 parts of magnesium stearate and 0.2 parts of magnesium stearate (i.e., both of them are lubricant) and 1.0 part of carbon black were added to the polypropylene resin composition. All of the components and additives were mixed with a tumbler, then, the mixture was melted and blended with a twin-screw extruder at 220C to obtain polypropylene resin compositions. The polypropylene resin composi.tions thus obtained were molded into test pieces with an injection molding machine under the conditions mentioned below;
- 1 o - 2~
(1) Injection molding machine; UBE MAX D150-10 (2) Shape of test piece;
rectangular, size: 36~ mm x 140 mm x 3 mm (test pieces for appearance measurement) rectangular, size: 50 mm x 90 mm x 2 mm (test pieces for painta~ility measurement) (3) Injection temperature; 220C
(4) Injection pressure; 980 kg/cm2 (5) Holding pressure; 4~0 kg/cm2 (6) Temperature of mold; 50C
The physical properties of the polypropylene resin compositions and those of the test pieces were measured as mentioned below:
(1) Melt flow index; according to AST~ D1238 (2) Gravity; according to ~STM D1505 (3) Brittle point temperature; according to JIS
(4) Izod impact strength; according to ASTM D256 (measured at -30C) (5) Flexural modulus; according to ASTM D790 (measured at 23C) (6) Surface hardness; according to ASTM D785 (7) Appearance of test piece; optically measured o; No stripe was seen on the surface ~; Stripe was seen on half of the area x; Stripe was seen on almost all of the area Paintability of the test pieces was measured as mentioned below. The test pieces were exposed to saturated vapor of 1,1,1-trichloroethane for 30 seconds to clean the surface of the test pieces, Then, the test pieces were placed in an oven kept at 90C for 10 minutes to dry.
Then the test pieces were treated with plasma under the conditions mentioned below:
(13 Pressure; l.0 torr (2) Microwave output; 0.05 kw (3) Treatlnent time; 0.3 sec.
(~) Gas flow; 600 cc/min.
(5) Gas; air.
After the plasma treatment, the test pieces were coated with one liquid-type polyurethane top coat paint at a thickness of 40 ~m. Then, dried at 120C for 30 min.; the test pieces were then left at room temperature for 48 hr.
The painted surfaces of the test pieces were cut with a knife into 100 squares, each of which had a size of 1 mm x 1 mm. Then, a sticking cellophane tape was applied on the surface and was peeled off, and thereafter the number of squares where the paint was peeled off was counted. In table 1, o indicates that there was no square where the paint was peeled off. ~ indicates that there were 1 to 10 squares where the paint was peeled off. x indicates that there were 11 or more squares where the paint was peeled off.
The components employed in the E~amples and Comparative Examples are mentioned below.
Component (A):
_ A-l A-2 A-3 A-4 A-5 (a) Ethylene 5.0 4.5 5.0 4.3 7.0 content (Wt%) _ (b) Boiling97.6 97.8 97.5 97.5 93.8 n-heptane insoluble fraction in the PP
(Wt~) .
(c) Intrinsic 4.1 4.5 4 . O 4 . 3 4 . 2 viscosity xylene soluble fraction _ (d) Melt-flow 43 47 28 35 42 (g/10 min.) (e) Flexural 18,500 19,000 18,100 18,000 15,600 modulus ( kg~cm2 ) Component (B):
¦ s-1 B-2 B-3 B-4 ¦ B-5 (a) Ethylene content (Wt%) 75 73 7575 75 (b) MLl~4(100C) _34 10 70 3472 Component (C):
_ C-l C-2 C-3 (a) MI (~/10 min.) 10 2 (b) Content of l-butene 8 10 4 _ (c) Gravity (g/ cm3 ) 0.90 0.89 0.92 2~.
Component (D):
¦(b) ML~ 00C) I D-l g Component (E):
E-l E-2 (a) Average diameter (~m) 2.4 3.5 (b) Portion of particle having O 4.6 diameter of lO ~m or more.
The evaluation results are as shown in Table 1.
_ _ ~ ,~1 _ _ _ ,~ _ ,1 ~, ___o _ o a~ c~ l l l ~ l l l ~ l ~ l ~ l ~ ~ ~` o ~ O
a~ ~ l l l ,1 l ~ l ~1 l ~ l ~1 l O a) o u) O
_ U~ __~ _ _ ~_ _ _ -'.'1~ ~ ~, ~, '01 ~D- O
~: ~ l ~7 l l ,1 l l l In l l ~ ,~ l o~ ,1 _ ~` U~ o u n l u~ l l ~1 l l l l ~1 ~ l ~1 l ~ ~( _ O ~D O
V ~ l u~ l l l l ,1 l ~ l a~ l ~ l C~`l ~ oo O ~ O
_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ~ ~ l l ~ l ~ l .' l l l l ,1 l ~ U~ ~ o ~ X
~ l l l ~rl l ~ l ' ~ ' ~ ' ,1 l _~ o U~ X
~1 - ~= l `,,, l -~ l l l l u~ l l o ~11 _.~ ul o u) l a:~ l l u) l l l c~ l ~ l ,1 l ~ o o o~ O
_ U~ _ _ ~t _ _ _ ~`I _ ~1 _~ ~i O--0 C~l 01~--O
~1 _ _ Irl _ _ _ ~ _ _ _ _ _ _ ~ _ ~ ~1 O ~D O
~ U~ l l l l ~ l ~1 l l ~1 l ~ l O ~ 0 O ~ O
_ ~1 ~U~ l l l ~ l l l r~l l CO l ~ l ~I ~ 06 O 1~ O
~ ~ ~ ~ ~3 6 ~ E~ ~ ~1 X
~ ~ I't ~ I' -~ ~ ~1~ _ _ ¢ I ¢ I ¢ I ¢ a~ 1 ~ v ~1~_ ~ ~ v I Q~ ~1 01 2~ ~ I ~ 10 1 ~ ~ P td Q~ 2) ~ a) a) ~ a) ~ o . P. ~ ~1 ~n Cd 1: ~ Ei ~ ~ .~ ~ ~ Ei ~ ~ ~ u a) u,~
JJ Ql ~ ~ ~ ~ P. ~I P~ ~ ~ a) ~ G ~I d ~ ~ ~ ~ ~ ~ ~ ~ td v ~ S ~ 0~ 0 $ O ,1: oP' ~ ~ ~ $ O ,~ 4 U ~1 ~ ~1 ~ ~ X ::s ~ ~ ~ O
,1 ~ )~ ~ o E~i ~ )J O ~ I O ~ O 0 O ~ S~ ~ ~ ~ ~1 0 ~ ~ ~ E~
1 U ~ ~ U ¢ U P4 U ~ U ¢ O ,n tJ E-l ~ ~ V H ~ ~ 13 0 ~' U~
~.q ~ L~
:~
~1 ~ ~1 l c~7 l U~ l O ~LD~ C~l O. ,~ ~D ~ ~i rl ~-o -- ~ - - -- - -0.
`o o o ~,q, _ _ ~- ~- -,~., ___ __ - ~ .0, - ~ O ., ~i ~i ~i l l ui l ~l l ~ l -l l ~ ~: : ~. o o ~ o e _ ,, l l ~ ~, l , l l l l O ~D, ~D ~i 0~ O I`i X ~:1 ~i oi l i l ~i l ,01 l ~ l l , r` ~ ~ u~ O ~ O O
~ci i a~ _ ~i _ ~i _~ _ ~D _~ _ U) ~`I 1~~ ~. O- ~1 O O
E~ _ _ _ _ _ _ _ _ _ ~( O _ r-l r-i _ _ _ ¦~i a~ U _ _ r-l _ ~i _ Ui _ Ui _ U~ O ~i ~ r-¦ 1~ O O
_ I~ ~ l l ui l r-l l ~ l I~ l _ O ~i ~.1 O _l O X
: ~ ~ ~ ~ ~i ~ t~ E~ t1.o i o' o _ ~ _ _ _ _ _ _ _ _ _ _ _ _ li ~ u~ ~ lui ~i C~ ~ C~l ~ ~ ~
¢ I ¢ iI ~i ~ ~ Li i ~ ~ .
~ ,~:: V a~ ~o u~
r-i ~J r-i L~l LV ~ ~J ~1 ~ tO
a~ :~ ~ ~ a v ~ r O ~ O O ~ ~ ~ ~ ~i P~
Lt ~ l ~1 l ~ ~rl ~rl J_) O )~ ~J
~P~ O ~ ;~ ~a 0 OE; ~d ~V ~rl r-l a o --t aLV V Lti ~ V Lti O ~ 1 4 r--l ~ S~ r~l r-i ~ C ) O ~ Ei ~ EiO 1 E; r-l P~ au E; ~i LU ~1 ~Q
ni av,~ au :~ au :~ .r:: ai p~ 41 ~ ,_1 ~r~ ~ C.) ~-I L~
r-i ~ ~ O ~ r-i ~ O t ) ~) rl IJ ~ ~ L~ au P~ ~1 OO ~5 ~ r~ ~O ,~ P~ r-l r-l Lll .~1 O ~V ~ ~ rl S I ~ l~i ~J O JJ O ~i ~ O ~i LV ~1 ~1 N r-l -) Q~ ~d V au ~ ¢ au o ~ o ~ E~ ~: ~ a: ~ ~ L/~
The physical properties of the polypropylene resin compositions and those of the test pieces were measured as mentioned below:
(1) Melt flow index; according to AST~ D1238 (2) Gravity; according to ~STM D1505 (3) Brittle point temperature; according to JIS
(4) Izod impact strength; according to ASTM D256 (measured at -30C) (5) Flexural modulus; according to ASTM D790 (measured at 23C) (6) Surface hardness; according to ASTM D785 (7) Appearance of test piece; optically measured o; No stripe was seen on the surface ~; Stripe was seen on half of the area x; Stripe was seen on almost all of the area Paintability of the test pieces was measured as mentioned below. The test pieces were exposed to saturated vapor of 1,1,1-trichloroethane for 30 seconds to clean the surface of the test pieces, Then, the test pieces were placed in an oven kept at 90C for 10 minutes to dry.
Then the test pieces were treated with plasma under the conditions mentioned below:
(13 Pressure; l.0 torr (2) Microwave output; 0.05 kw (3) Treatlnent time; 0.3 sec.
(~) Gas flow; 600 cc/min.
(5) Gas; air.
After the plasma treatment, the test pieces were coated with one liquid-type polyurethane top coat paint at a thickness of 40 ~m. Then, dried at 120C for 30 min.; the test pieces were then left at room temperature for 48 hr.
The painted surfaces of the test pieces were cut with a knife into 100 squares, each of which had a size of 1 mm x 1 mm. Then, a sticking cellophane tape was applied on the surface and was peeled off, and thereafter the number of squares where the paint was peeled off was counted. In table 1, o indicates that there was no square where the paint was peeled off. ~ indicates that there were 1 to 10 squares where the paint was peeled off. x indicates that there were 11 or more squares where the paint was peeled off.
The components employed in the E~amples and Comparative Examples are mentioned below.
Component (A):
_ A-l A-2 A-3 A-4 A-5 (a) Ethylene 5.0 4.5 5.0 4.3 7.0 content (Wt%) _ (b) Boiling97.6 97.8 97.5 97.5 93.8 n-heptane insoluble fraction in the PP
(Wt~) .
(c) Intrinsic 4.1 4.5 4 . O 4 . 3 4 . 2 viscosity xylene soluble fraction _ (d) Melt-flow 43 47 28 35 42 (g/10 min.) (e) Flexural 18,500 19,000 18,100 18,000 15,600 modulus ( kg~cm2 ) Component (B):
¦ s-1 B-2 B-3 B-4 ¦ B-5 (a) Ethylene content (Wt%) 75 73 7575 75 (b) MLl~4(100C) _34 10 70 3472 Component (C):
_ C-l C-2 C-3 (a) MI (~/10 min.) 10 2 (b) Content of l-butene 8 10 4 _ (c) Gravity (g/ cm3 ) 0.90 0.89 0.92 2~.
Component (D):
¦(b) ML~ 00C) I D-l g Component (E):
E-l E-2 (a) Average diameter (~m) 2.4 3.5 (b) Portion of particle having O 4.6 diameter of lO ~m or more.
The evaluation results are as shown in Table 1.
_ _ ~ ,~1 _ _ _ ,~ _ ,1 ~, ___o _ o a~ c~ l l l ~ l l l ~ l ~ l ~ l ~ ~ ~` o ~ O
a~ ~ l l l ,1 l ~ l ~1 l ~ l ~1 l O a) o u) O
_ U~ __~ _ _ ~_ _ _ -'.'1~ ~ ~, ~, '01 ~D- O
~: ~ l ~7 l l ,1 l l l In l l ~ ,~ l o~ ,1 _ ~` U~ o u n l u~ l l ~1 l l l l ~1 ~ l ~1 l ~ ~( _ O ~D O
V ~ l u~ l l l l ,1 l ~ l a~ l ~ l C~`l ~ oo O ~ O
_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ~ ~ l l ~ l ~ l .' l l l l ,1 l ~ U~ ~ o ~ X
~ l l l ~rl l ~ l ' ~ ' ~ ' ,1 l _~ o U~ X
~1 - ~= l `,,, l -~ l l l l u~ l l o ~11 _.~ ul o u) l a:~ l l u) l l l c~ l ~ l ,1 l ~ o o o~ O
_ U~ _ _ ~t _ _ _ ~`I _ ~1 _~ ~i O--0 C~l 01~--O
~1 _ _ Irl _ _ _ ~ _ _ _ _ _ _ ~ _ ~ ~1 O ~D O
~ U~ l l l l ~ l ~1 l l ~1 l ~ l O ~ 0 O ~ O
_ ~1 ~U~ l l l ~ l l l r~l l CO l ~ l ~I ~ 06 O 1~ O
~ ~ ~ ~ ~3 6 ~ E~ ~ ~1 X
~ ~ I't ~ I' -~ ~ ~1~ _ _ ¢ I ¢ I ¢ I ¢ a~ 1 ~ v ~1~_ ~ ~ v I Q~ ~1 01 2~ ~ I ~ 10 1 ~ ~ P td Q~ 2) ~ a) a) ~ a) ~ o . P. ~ ~1 ~n Cd 1: ~ Ei ~ ~ .~ ~ ~ Ei ~ ~ ~ u a) u,~
JJ Ql ~ ~ ~ ~ P. ~I P~ ~ ~ a) ~ G ~I d ~ ~ ~ ~ ~ ~ ~ ~ td v ~ S ~ 0~ 0 $ O ,1: oP' ~ ~ ~ $ O ,~ 4 U ~1 ~ ~1 ~ ~ X ::s ~ ~ ~ O
,1 ~ )~ ~ o E~i ~ )J O ~ I O ~ O 0 O ~ S~ ~ ~ ~ ~1 0 ~ ~ ~ E~
1 U ~ ~ U ¢ U P4 U ~ U ¢ O ,n tJ E-l ~ ~ V H ~ ~ 13 0 ~' U~
~.q ~ L~
:~
~1 ~ ~1 l c~7 l U~ l O ~LD~ C~l O. ,~ ~D ~ ~i rl ~-o -- ~ - - -- - -0.
`o o o ~,q, _ _ ~- ~- -,~., ___ __ - ~ .0, - ~ O ., ~i ~i ~i l l ui l ~l l ~ l -l l ~ ~: : ~. o o ~ o e _ ,, l l ~ ~, l , l l l l O ~D, ~D ~i 0~ O I`i X ~:1 ~i oi l i l ~i l ,01 l ~ l l , r` ~ ~ u~ O ~ O O
~ci i a~ _ ~i _ ~i _~ _ ~D _~ _ U) ~`I 1~~ ~. O- ~1 O O
E~ _ _ _ _ _ _ _ _ _ ~( O _ r-l r-i _ _ _ ¦~i a~ U _ _ r-l _ ~i _ Ui _ Ui _ U~ O ~i ~ r-¦ 1~ O O
_ I~ ~ l l ui l r-l l ~ l I~ l _ O ~i ~.1 O _l O X
: ~ ~ ~ ~ ~i ~ t~ E~ t1.o i o' o _ ~ _ _ _ _ _ _ _ _ _ _ _ _ li ~ u~ ~ lui ~i C~ ~ C~l ~ ~ ~
¢ I ¢ iI ~i ~ ~ Li i ~ ~ .
~ ,~:: V a~ ~o u~
r-i ~J r-i L~l LV ~ ~J ~1 ~ tO
a~ :~ ~ ~ a v ~ r O ~ O O ~ ~ ~ ~ ~i P~
Lt ~ l ~1 l ~ ~rl ~rl J_) O )~ ~J
~P~ O ~ ;~ ~a 0 OE; ~d ~V ~rl r-l a o --t aLV V Lti ~ V Lti O ~ 1 4 r--l ~ S~ r~l r-i ~ C ) O ~ Ei ~ EiO 1 E; r-l P~ au E; ~i LU ~1 ~Q
ni av,~ au :~ au :~ .r:: ai p~ 41 ~ ,_1 ~r~ ~ C.) ~-I L~
r-i ~ ~ O ~ r-i ~ O t ) ~) rl IJ ~ ~ L~ au P~ ~1 OO ~5 ~ r~ ~O ,~ P~ r-l r-l Lll .~1 O ~V ~ ~ rl S I ~ l~i ~J O JJ O ~i ~ O ~i LV ~1 ~1 N r-l -) Q~ ~d V au ~ ¢ au o ~ o ~ E~ ~: ~ a: ~ ~ L/~
Claims (8)
1. A polypropylene resin composition comprising:
(A) 45 to 70% by weight of an ethylene-propylene block copolymer synthesized under the process comprising the steps of;
(a) polymerizing propylene with a Ziegler-Natta catalyst to obtain a highly crystalline polypropylene that contain not less than 97% by weight of a fraction insoluble in boiling n-heptane, and (b) copolymerizing ethylene with the polypropylene (a), and which (a) contains 0.5 to 10% by weight of ethylene, (b) contains 5 to 20% by weight of a fraction being soluble in p-xylene at room temperature and having an intrinsic viscosity value of not less than 2 (measured in decalin at 135°C), (c) has a melt-flow index value of 30 to 100 g/10 min., and, (d) has a value of flexural modulus of not less than 18,000 kg/cm2, (B) 10 to 20% by weight of an amorphous ethylene-propylene copolymer having (a) an ethylene content of 70 to 90% by weight, (b) a Mooney viscosity value (ML1+4 at 100°C) of 5 to 20, (C) 5 to 15% by weight of an ethylene-.alpha.-olefin copolymer having (a) an .alpha.-olefin content of 5 to 15% by mole, (b) a value of gravity of not more than 0.91, and (c) a melt-flow index value of 2.2 to 50 g/10 min. at 230°C, (D) 1 to 10% by weight of an amorphous ethylene-butene copolymer having (a) a butene content of 10 to 25% by weight, and (b) a Mooney viscosity value (ML1+4, at 100°C) of 5 to 20, (E) not more than 15% by weight of a talc that (a) has an average diameter D50 of from 1.0 to 3.0 µm, and (b) does not contain a particle having a diameter of 10 µm or more, wherein the component (B) is rubber reinforced by lamellae of components (C) and (D).
(A) 45 to 70% by weight of an ethylene-propylene block copolymer synthesized under the process comprising the steps of;
(a) polymerizing propylene with a Ziegler-Natta catalyst to obtain a highly crystalline polypropylene that contain not less than 97% by weight of a fraction insoluble in boiling n-heptane, and (b) copolymerizing ethylene with the polypropylene (a), and which (a) contains 0.5 to 10% by weight of ethylene, (b) contains 5 to 20% by weight of a fraction being soluble in p-xylene at room temperature and having an intrinsic viscosity value of not less than 2 (measured in decalin at 135°C), (c) has a melt-flow index value of 30 to 100 g/10 min., and, (d) has a value of flexural modulus of not less than 18,000 kg/cm2, (B) 10 to 20% by weight of an amorphous ethylene-propylene copolymer having (a) an ethylene content of 70 to 90% by weight, (b) a Mooney viscosity value (ML1+4 at 100°C) of 5 to 20, (C) 5 to 15% by weight of an ethylene-.alpha.-olefin copolymer having (a) an .alpha.-olefin content of 5 to 15% by mole, (b) a value of gravity of not more than 0.91, and (c) a melt-flow index value of 2.2 to 50 g/10 min. at 230°C, (D) 1 to 10% by weight of an amorphous ethylene-butene copolymer having (a) a butene content of 10 to 25% by weight, and (b) a Mooney viscosity value (ML1+4, at 100°C) of 5 to 20, (E) not more than 15% by weight of a talc that (a) has an average diameter D50 of from 1.0 to 3.0 µm, and (b) does not contain a particle having a diameter of 10 µm or more, wherein the component (B) is rubber reinforced by lamellae of components (C) and (D).
2. A polypropylene composition as claimed in claim 1, wherein the content of component (E) is 8 to 15%
by weight.
by weight.
3. A polypropylene composition as claimed in claim 1, wherein the content of component (E) is less than 8% by weight.
4. A polypropylene composition as claimed in claim 1, wherein the ethylene component of component (A) is 1.5 to 7.0% by weight.
5. A polypropylene composition as claimed in claim 1, wherein the component (A) has a polypropylene component containing 97.5% by weight or more of a fraction which is insoluble in a boiling n-heptane.
6. A polypropylene composition as claimed in claim 1, wherein the component (A) has a p-xylene soluble fraction having an intrinsic viscosity value of from 3 to 12.
7. A polypropylene composition as claimed in claim 1, wherein the component (C) is a copolymer of ethylene and a C4 to C10 .alpha.-olefin.
8. A polypropylene composition as claimed in claim 1, wherein the component (C) is a copolymer of ethylene and 1-butene.
Applications Claiming Priority (4)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP24423191A JP2859003B2 (en) | 1991-08-30 | 1991-08-30 | Resin composition for bumper |
| JP3-244231 | 1991-08-30 | ||
| JP28941291A JP3119691B2 (en) | 1991-10-09 | 1991-10-09 | Resin composition for bumper |
| JP3-289412 | 1991-10-09 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA2077033A1 true CA2077033A1 (en) | 1993-03-01 |
Family
ID=26536633
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA002077033A Abandoned CA2077033A1 (en) | 1991-08-30 | 1992-08-27 | Polypropylene resin composition |
Country Status (5)
| Country | Link |
|---|---|
| US (1) | US5308908A (en) |
| EP (1) | EP0531054B1 (en) |
| CA (1) | CA2077033A1 (en) |
| DE (2) | DE69226055T4 (en) |
| ES (1) | ES2118113T3 (en) |
Families Citing this family (36)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CA2093197A1 (en) * | 1992-06-04 | 1993-12-05 | Yoshiharu Saito | Resin composition having excellent paint coatability |
| EP0657500B1 (en) * | 1993-06-30 | 1998-09-30 | Mitsui Chemicals, Inc. | Polypropylene composition |
| IT1264555B1 (en) * | 1993-08-03 | 1996-10-02 | Himont Inc | SLUSH MOLDING PROCESS OF POLYOLEFINIC COMPOSITIONS POWDERS |
| JP2802023B2 (en) * | 1993-08-10 | 1998-09-21 | 宇部興産株式会社 | Reinforced polypropylene resin composition |
| JP3031142B2 (en) * | 1993-11-01 | 2000-04-10 | 住友化学工業株式会社 | Polypropylene resin composition |
| US6087429A (en) * | 1993-11-24 | 2000-07-11 | Mitsubishi Chemical Corporation | Propylene resin composition |
| AU689895B2 (en) * | 1994-07-11 | 1998-04-09 | Tonen Chemical Corporation | Polypropylene resin composition |
| DE69513237T2 (en) * | 1994-08-02 | 2000-04-13 | Chisso Corp | Polyolefin resin composition for automotive interior clothing |
| JP2839840B2 (en) * | 1994-08-19 | 1998-12-16 | 昭和電工株式会社 | Propylene resin composition |
| US5763534A (en) * | 1994-08-25 | 1998-06-09 | Solvay Engineered Polymers | Thermoplastic polypropylene blends with mixtures of ethylene/butene and ethylene/octene copolymer elastomers |
| US5747592A (en) * | 1994-12-16 | 1998-05-05 | Exxon Chemical Patents, Inc. | Thermoplastic polymer compositions and their production and use |
| JP3414549B2 (en) * | 1995-04-27 | 2003-06-09 | 住友化学工業株式会社 | Thermoplastic resin composition and injection molded article thereof |
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| US20060052541A1 (en) * | 2002-06-25 | 2006-03-09 | Erling Hagen | Polyolefin with improved scratch resistance and process for producing the same |
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| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US4229504A (en) * | 1978-07-31 | 1980-10-21 | Bethlehem Steel Corporation | Polyolefin composition having high impact resistance and high temperature flow resistance |
| JPS603420B2 (en) * | 1980-09-22 | 1985-01-28 | 宇部興産株式会社 | Polypropylene composition for bumpers |
| JPS5949252B2 (en) * | 1981-03-30 | 1984-12-01 | 宇部興産株式会社 | polypropylene composition |
| JPS57195134A (en) * | 1981-05-27 | 1982-11-30 | Sumitomo Chem Co Ltd | Resin composition containing inorganic filler |
| JPS57207630A (en) * | 1981-06-15 | 1982-12-20 | Toa Nenryo Kogyo Kk | Thermoplastic resin composition |
| JPS5817139A (en) * | 1981-07-23 | 1983-02-01 | Sumitomo Chem Co Ltd | Novel polypropylene resin composition |
| JPS6031868B2 (en) * | 1981-12-25 | 1985-07-24 | 宇部興産株式会社 | polypropylene composition |
| JPS62112644A (en) * | 1985-11-11 | 1987-05-23 | Nippon Petrochem Co Ltd | Non-rigid polyolefin composition |
| JPS6466263A (en) * | 1987-09-07 | 1989-03-13 | Chisso Corp | Resin composition for automobile exterior parts |
| JPH0725985B2 (en) * | 1988-11-21 | 1995-03-22 | 宇部興産株式会社 | Polypropylene composition |
-
1992
- 1992-08-27 CA CA002077033A patent/CA2077033A1/en not_active Abandoned
- 1992-08-28 US US07/936,389 patent/US5308908A/en not_active Expired - Fee Related
- 1992-08-28 DE DE69226055T patent/DE69226055T4/en not_active Expired - Lifetime
- 1992-08-28 ES ES92307833T patent/ES2118113T3/en not_active Expired - Lifetime
- 1992-08-28 DE DE69226055A patent/DE69226055D1/en not_active Expired - Fee Related
- 1992-08-28 EP EP92307833A patent/EP0531054B1/en not_active Expired - Lifetime
Also Published As
| Publication number | Publication date |
|---|---|
| DE69226055T2 (en) | 1999-02-25 |
| DE69226055T4 (en) | 2000-02-24 |
| EP0531054A2 (en) | 1993-03-10 |
| EP0531054B1 (en) | 1998-07-01 |
| DE69226055D1 (en) | 1998-08-06 |
| US5308908A (en) | 1994-05-03 |
| EP0531054A3 (en) | 1993-04-07 |
| ES2118113T3 (en) | 1998-09-16 |
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| EEER | Examination request | ||
| FZDE | Discontinued |