WO2024189596A1 - Composition composite de polypropylène - Google Patents

Composition composite de polypropylène Download PDF

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Publication number
WO2024189596A1
WO2024189596A1 PCT/IB2024/052543 IB2024052543W WO2024189596A1 WO 2024189596 A1 WO2024189596 A1 WO 2024189596A1 IB 2024052543 W IB2024052543 W IB 2024052543W WO 2024189596 A1 WO2024189596 A1 WO 2024189596A1
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WO
WIPO (PCT)
Prior art keywords
weight
polypropylene
composite composition
polypropylene composite
impact copolymer
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Ceased
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PCT/IB2024/052543
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English (en)
Inventor
Sairam T C N
Sharath PRASAD
Adithya BHARADWAJ
Anjan ROY
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Reliance Industries Ltd
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Reliance Industries Ltd
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Publication of WO2024189596A1 publication Critical patent/WO2024189596A1/fr
Anticipated expiration legal-status Critical
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    • 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
    • C08L23/10—Homopolymers or copolymers of propene
    • C08L23/14—Copolymers of propene
    • C08L23/142—Copolymers of propene at least partially crystalline copolymers of propene with other olefins

Definitions

  • the present disclosure relates to a polypropylene composite composition, and more particularly to a polypropylene composite composition for telecom products/devices.
  • the disclosure herein provides a polypropylene composite composition.
  • the present disclosure provides a polypropylene composite composition comprising a mixture of polypropylene impact copolymers; and optionally, an additive.
  • the present disclosure provides a polypropylene composite composition comprising about 60% to about 90% by weight of a mixture of polypropylene impact copolymers; and remaining is optionally additive.
  • the present disclosure provides a polypropylene composite composition having high elongation at yield and low MFI.
  • the present disclosure provides an article or component produced by molding the polypropylene composite composition as described herein.
  • Figure 1 illustrates isobaric PVT measurement of the polypropylene composite composition of Example 1.
  • Figure 2 illustrates DSC Thermogram (heat flow as a function of temperature) of the polypropylene composite composition of Example 1.
  • Figure 3 illustrates DSC Thermogram (specific heat capacity as a function of temperature) the polypropylene composite composition of Example 1.
  • FIG. 4 illustrates housings made with polypropylene pellets in accordance with an embodiment.
  • an element means one element or more than one element.
  • the present disclosure provides a polypropylene composite composition.
  • the present disclosure provides a polypropylene composite composition satisfying the following property requirements: tensile strength of more than about 15 Mpa; flexural modulus of more than about 1500; flexural strength of more than about 25 Mpa; Izod impact (notch) of more than about 200 J/m; dielectric constant of about 2 to about 3 at 5 Hz; dielectric strength of more than about 21.2 kV/mm; heat distortion temperature (HDT) of more than about 90 °C; and flammability (horizontal-burning, HB); and/or color (AE ⁇ 1) of Pantone 533C.
  • the polypropylene composite composition comprises a mixture of polypropylene impact copolymers; and optionally, an additive.
  • the polypropylene composite composition comprises a mixture of polypropylene impact copolymers; a polypropylene homopolymer (PPHP); and optionally, one or more additives.
  • the PPHP may present in from about 5% to about 24% by weight, about 5% to 15% by weight, or about 10% to about 25% by weight. Any PPHP known in the art may be used.
  • the term "homopolymer" refers to a polymer comprising repeating units originating from a single type of monomer. However, it does not preclude the presence of residual quantities of other substances utilized in the production process of the homopolymer.
  • the PPHP is Repol Hl 10MA.
  • Polypropylene impact copolymers as used herein refer to impact copolymers which contain a propylene homopolymer containing a co-mixed propylene random copolymer phase which has an ethylene content of about 5-30%.
  • the polypropylene composite composition comprises about 60% to about 90% by weight of a mixture of polypropylene impact copolymers; and remaining is optionally additive.
  • the mixture of polypropylene impact copolymers comprises about 10% to about 50% by weight of a first polypropylene impact copolymer; and about 20% to about 70% by weight of a second polypropylene impact copolymer; wherein the second polypropylene impact copolymer is different than the first polypropylene impact copolymer.
  • the mixture comprises about 20% to about 50%, about 25% to about 50%, or about 30% to about 50% by weight of a first polypropylene impact copolymer; and about 25% to about 70%, about 30% to about 70%, about 25% to about 65%, about 25% to about 60%; or about 25% to about 55% by weight of a second polypropylene impact copolymer; wherein the second polypropylene impact copolymer is different than the first polypropylene impact copolymer.
  • the first polypropylene impact copolymer has medium impact strength. In some embodiments, the first polypropylene impact copolymer has medium impact strength of about 150 J/m. Any polypropylene impact copolymer having medium impact strength may be used as the first polypropylene impact copolymer.
  • the first polypropylene impact copolymer may be prepared to satisfy the said-mentioned property requirements using a conventional method known in the art or may be commercially obtained and used. In an exemplary embodiment, Repol C320MN, Repol B650MN, Repol B300MN, and/or Repol D120MA is used as the first polypropylene impact copolymer.
  • a second polypropylene impact copolymer is added to the composition.
  • the second polypropylene impact copolymer is high crystalline impact copolymer polypropylene.
  • the second polypropylene impact copolymer may be prepared to satisfy the said-mentioned property requirements using a conventional method known in the art or may be commercially obtained and used.
  • Repol HCPP B300MN is used as the second polypropylene impact copolymer.
  • Repol C080MA is used as high impact copolymer polypropylene.
  • the polypropylene in the composition may be a recycled polypropylene.
  • the term “recycled polypropylene” refers to a polypropylene polymer that has been previously utilized and then recycled again.
  • the recycled polypropylene is post-consumer recycled polypropylene (PCR-PP).
  • PCR-PP has advantageous in some cases, including: (i) a 20-30% reduction in carbon footprint compared to producing virgin PP; (ii) energy savings of up to 3.5 kWh per pound of recycled PP versus producing new PP; (iii) about 30% decrease in plastic waste sent to landfills; and (iv) about 5% reduction in material costs.
  • the polypropylene composite composition may further comprise an additive.
  • the additive is selected from a group comprising a stiffener, a modifier, colorant, a scratch resistance agent, UV resistance agent, an antioxidant, a lubricant, and a combination thereof.
  • the polypropylene composite composition may comprise a stiffener.
  • the stiffener may present in about 10% to about 30% by weight. In certain embodiments, the stiffener may present in about 10% to about 25% by weight or about 15% to about 25% by weight, or about 10% to about 20% by weight. In some instances, the stiffener may present in about 10%, about 11%, about 12%, about 13%, about 14%, about 15%, about 16%, about 17%, about 18%, about 19%, about 20%, about 21%, about 22%, about 23%, about 24%, about 25%, about 26%, about 27%, about 28%, about 29%, or about 30% by weight. Any stiffener known in the art may be used. Examples of stiffener include, but are not limited to, talc (such as micro talc and soapstone, etc.), calcium carbonate, glass and combinations thereof.
  • the polypropylene composite composition may comprise a modifier.
  • the modifier may present in about 1% to about 10% by weight. In certain embodiments, the modifier may present in about 1% to about 8% by weight, or about 2% to about 10% by weight, or about 1% to about 5% by weight, or about 5% to about 10% by weight. In some instances, the modifier may present in about 1%, about 2%, about 3%, about 4%, about 5%, about 6%, about 7%, about 8%, about 9%, or about 10% by weight. Any modifier known in the art may be used. Examples of modifier include, but are not limited to, process, optical, tensile, flammability and combinations thereof. In certain embodiments, the modifier is a polyolefin elastomer. Non-limiting examples of polyolefin elastomer include, but are not limited to, ethylene-octene (EO) polyolefin elastomer (POE) and the like.
  • EO ethylene-octene
  • the polypropylene composite composition may comprise a colorant.
  • the colorant may present in about 1% to about 8% by weight, or about 1% to about 7% by weight, or about 2% to about 8% by weight, or about 1% to about 6% by weight, or about 2% to about 8% by weight. In some instances, the colorant may present in about 1%, about 2%, about 3%, about 4%, about 5%, about 6%, about 7%, or about 8% by weight.
  • Any colorant known in the art may be used. Examples of colorant include, but are not limited to, organic pigments, inorganic pigments and combinations thereof. Any pigment known in the art or commercially available may be used.
  • the polypropylene composite composition may comprise a scratch resistance agent.
  • the scratch resistance agent may present in about 0.1 % to about 2% by weight, or 0.1% to about 1.5% by weight. In some instances, the scratch resistance agent may present in about 0.1%, about 0.15%, about 0.2%, about 0.25%, about 0.3%, about 0.35%, about 0.4%, about 0.45%, about 0.5%, about 0.55%, about 0.6%, about 0.65%, about 0.7%, about 0.75%, about 0.8%, about 0.85%, about 0.9%, about 0.95%, about 1%, about 1.05%, about 1.1%, about 1.15%, about 1.2%, about 1.25%, about 1.3%, about 1.35%, about 1.4%, about 1.45%, about 1.5%, about 1.55%, about 1.6%, about 1.65%, 1.7%, about 1.75%, about 1.8%, about 1.85%, about 1.9%, or about 2% by weight.
  • scratch resistance agent Any scratch resistance agent known in the art may be used.
  • scratch resistance agent include, but are not limited to, bio-based fatty acid or silicone or mica based and combinations thereof.
  • the scratch resistance agent is an organosilicone or oleochemical. Any organosilicone known in the art or commercially available may be used.
  • the polypropylene composite composition may comprise a UV resistance agent.
  • the UV resistance agent may present in about 0.001% to about 3% by weight, or about 0.001% to about 2% by weight, or about 0.01% to about 3% by weight.
  • the UV resistance agent may present in about 0.001%, about 0.001%, about 0.002%, about 0.003%, about 0.004%, about 0.005%, about 0.006%, about 0.007%, about 0.008%, about 0.009%, about 0.01%, about 0.02%, about 0.03%, about 0.04%, about 0.05%, about 0.06%, about 0.07%, about 0.08%, about 0.09%, about 0.1%, about 0.15%, about 0.2%, about 0.25%, about 0.3%, about 0.35%, about 0.4%, about 0.45%, about 0.5%, about 0.55%, about 0.6%, about 0.65%, about 0.7%, about 0.75%, about 0.8%, about 0.85%, about 0.9%, about 0.95%, about 1%, about 1.05%,
  • UV resistance agent Any UV resistance agent known in the art may be used.
  • UV resistance agent include, but are not limited to, silicone based, hindered amine type light stabilizers and combinations thereof. Any hindered amine type light stabilizer known in the art or commercially available may be used.
  • the polypropylene composite composition may comprise an antioxidant.
  • the antioxidant may present in about 0.1% to about 3% by weight, or 0.1% to about 2.5% by weight, or 0.2% to about 3% by weight, or about 0.5% to about 3% by weight. In some instances, the antioxidant may present in about 0.1%, about 0.15%, about 0.2%, about 0.25%, about 0.3%, about 0.35%, about 0.4%, about 0.45%, about 0.5%, about 0.55%, about 0.6%, about 0.65%, about 0.7%, about 0.75%, about 0.8%, about 0.85%, about 0.9%, about 0.95%, about 1%, about 1.05%, about 1.1%, about 1.15%, about 1.2%, about 1.25%, about 1.3%, about 1.35%, about 1.4%, about 1.45%, about 1.5%, about 1.55%, about 1.6%, about 1.65%, 1.7%, about 1.75%, about 1.8%, about 1.85%, about 1.9%, about 2%, about 2.05%, about 2.1%, about 2.15%, about 2.2%, about 2.25%
  • antioxidant Any antioxidant known in the art may be used.
  • examples of antioxidant include, but are not limited to, phenolic such as pentaerythritol tetrakis(3-(3,5-di-tert-butyl-4- hydroxyphenyl)propionate and the like.
  • the polypropylene composite composition may comprise a lubricant.
  • the lubricant may present in about 0.1% to about 2% by weight, or 0.1% to about 1.5% by weight. In some instances, the lubricant may present in about 0.1%, about 0.15%, about 0.2%, about 0.25%, about 0.3%, about 0.35%, about 0.4%, about 0.45%, about 0.5%, about 0.55%, about 0.6%, about 0.65%, about 0.7%, about 0.75%, about 0.8%, about 0.85%, about 0.9%, about 0.95%, about 1%, about 1.05%, about 1.1%, about 1.15%, about 1.2%, about 1.25%, about 1.3%, about 1.35%, about 1.4%, about 1.45%, about 1.5%, about 1.55%, about 1.6%, about 1.65%, 1.7%, about 1.75%, about 1.8%, about 1.85%, about 1.9%, or about 2% by weight. Any lubricant known in the art may be used. Examples of lubricant include, but are not limited to, calcium phosphate
  • the polypropylene composite composition may comprise a stiffener, a modifier, colorant, a scratch resistance agent, UV resistance agent, an antioxidant, and a lubricant.
  • the polypropylene composite composition comprises about 60% to about 90% by weight of a mixture of polypropylene impact copolymers; and optionally, remaining is additive; wherein the additive is selected from a group comprising a stiffener, a modifier, colorant, a scratch resistance agent, UV resistance agent, an antioxidant, a lubricant, and a combination thereof.
  • the polypropylene composite composition may further comprise PPHP.
  • the PPHP may present in from about 5% to about 24% by weight, about 5% to 15% by weight, or about 10% to about 25% by weight. In some embodiments, the PPHP is same as defined above.
  • the polypropylene composite composition comprises about 10% to about 50% by weight of a first polypropylene impact copolymer; about 20% to about 70% by weight of a second polypropylene impact copolymer; and optionally, remaining is additive; wherein the second polypropylene impact copolymer is different than the first polypropylene impact copolymer; and the additive is selected from a group comprising a stiffener, a modifier, colorant, a scratch resistance agent, UV resistance agent, an antioxidant, a lubricant, and a combination thereof.
  • the polypropylene composite composition comprises about 10% to about 50% by weight of a first polypropylene impact copolymer; and about 20% to about 70% by weight of a second polypropylene impact copolymer; about 10% to about 30% by weight stiffener; and optionally, remaining is additive; wherein the second polypropylene impact copolymer is different than the first polypropylene impact copolymer; and the additive is selected from a group comprising a modifier, colorant, a scratch resistance agent, UV resistance agent, an antioxidant, a lubricant, and a combination thereof.
  • the polypropylene composite composition comprises about 10% to about 50% by weight of a first polypropylene impact copolymer; about 20% to about 70% by weight of a second polypropylene impact copolymer; about 10% to about 30% by weight of a stiffener; about 1% to about 10% by weight of modifier; and optionally, remaining is additive; wherein the second polypropylene impact copolymer is different than the first polypropylene impact copolymer; and the additive is selected from a group comprising colorant, a scratch resistance agent, UV resistance agent, an antioxidant, a lubricant, and a combination thereof.
  • the polypropylene composite composition comprises about 10% to about 50% by weight of a first polypropylene impact copolymer; about 20% to about 70% by weight of a second polypropylene impact copolymer; about 10% to about 30% by weight of a stiffener; about 1% to about 10% by weight of modifier; about 1% to about 8% by weight of a colorant; and optionally, remaining is additive; wherein the second polypropylene impact copolymer is different than the first polypropylene impact copolymer; and the additive is selected from a group comprising a scratch resistance agent, UV resistance agent, an antioxidant, a lubricant, and a combination thereof.
  • the polypropylene composite composition comprises about 10% to about 50% by weight of a first polypropylene impact copolymer; about 20% to about 70% by weight of a second polypropylene impact copolymer; about 10% to about 30% by weight of a stiffener; about 1% to about 10% by weight of modifier; about 1% to about 8% by weight of a colorant; and remaining is additive; wherein the second polypropylene impact copolymer is different than the first polypropylene impact copolymer; and the additive is selected from a group comprising a scratch resistance agent, UV resistance agent, an antioxidant, a lubricant, and a combination thereof.
  • the polypropylene composite composition comprises about 10% to about 50% by weight of a first polypropylene impact copolymer; about 20% to about 70% by weight of a second polypropylene impact copolymer; about 10% to about 30% by weight of a stiffener; about 1% to about 10% by weight of modifier; about 1% to about 8% by weight of a colorant; about 0.1 % to about 2% by weight of a scratch resistance agent; about 0.001% to about 3% by weight of a UV resistance agent; in about 0.1% to about 3% by weight of an antioxidant; and about 0.1 % to about 2% by weight of a lubricant; wherein the second polypropylene impact copolymer is different than the first polypropylene impact copolymer.
  • the polypropylene composite provided by the present disclosure has high elongation at yield and low MFI. In further embodiments, the polypropylene composite provided by the present disclosure has high elongation at yield and low MFI while maintaining low shrinkage and/or higher HDT (Heat deflection temperature).
  • the polypropylene composite provided by the present disclosure has high elongation at yield and low MFI while maintaining low shrinkage and higher HDT at 0.45MPa.
  • the polypropylene composite composition provided by the present disclosure exhibits (i) mold flow index (MFI) of about 21.484 g/10 min; (ii) mold shrinkage of about 0.92 %, and/or (iii) dissipation factor value of about 2.75E-02 at 1 KHz.
  • the polypropylene composite composition provided herein can be molded into an article or component or part having no flow mark, waviness, and/or voids on the surface.
  • the polypropylene composite composition provided herein is suitable for injection molding process to yield the articles or components.
  • the polypropylene composite composition is suitable for injection molding process yielding components with mold flow index (MFI) of 21.484 g/lOmin, mold shrinkage of 0.92% having no flow marks, voids, waviness, etc.
  • the article is an enclosure for an electronic, an electrical or a telecommunication device.
  • the polypropylene composite composition provided herein is well placed between commodity and engineering plastic.
  • the material is suited for applications for electronic/telecom enclosures which is not suitable with commodity plastic but at the same time not suitable for high-end/mobile/aesthetically superior devices.
  • the polypropylene composite composition provided herein has acceptable dissipation factor values which makes it suitable to be used for telecom devices with antenna for signal transmission/reception.
  • the polypropylene composite composition provided herein has HB (horizontal-burning) flammability rating as per UL-94 standards. Thus, it is suitable to be used for low DC voltage applications.
  • the polypropylene composite composition provided herein is useful in making plastic housings/enclosures for electronic devices with low DC current carrying capacity.
  • the polypropylene composite composition provided herein is useful in making plastic housings or enclosures for house-hold appliances, loT devices automobiles, and the like.
  • the polypropylene composite composition provided herein is of low cost compared to existing material used in fixed devices. For instance, the polypropylene composite composition provided herein costs 35-50% less than PC/PC-ABS or ABS material used in the fixed devices.
  • the present disclosure also provides a process for preparing a polypropylene composite composition satisfying the composition and content conditions as described above.
  • the process for preparing the polypropylene composite composition may be prepared by compounding all the components such as polypropylenes and optionally additive(s) of the composition.
  • the polypropylenes and the additive(s) are the same as described above.
  • Compounding is a process where all the components are mixed together in different quantities, melted, and blended to yield a composition.
  • the compounding can be done in a compounding machine or device. Any compounding machine may be used in the process.
  • the polypropylene composite composition of the present disclosure is typically produced by compounding all the components in an extruder. All components, the polypropylenes and optionally the additive can be compounded together in an extruder.
  • the compounding is done in an extruder at a predetermined pressure and temperature. In some embodiments, the compounding is done at a temperature of about 200 °C to about 250 °C. In some embodiments, the compounding is done at a temperature of about 205 °C to about 220 °C. In some instances, the compounding is done at a temperature of about 205 °C, about 210 °C, about 215 °C, and/or about 220 °C.
  • the compounding pressure is about 550 to 650 mm/Hg or about 600 mm/Hg.
  • a polypropylene composite composition was prepared. The details of the composition and process are depicted in Table 1 and Table 2, respectively.
  • Table 1 contains details of composition for polypropylene composite compounding.
  • the first polypropylene impact copolymer with 30-70% composition was mixed with second polypropylene impact copolymer (high crystalline impact copolymer) with 15-50%.
  • the ratio between the first polypropylene impact copolymer and second polypropylene impact copolymer achieved right target values and balance stiffness and impact properties.
  • the first polypropylene impact copolymer has medium impact strength.
  • a second polypropylene impact copolymer was added to the composition.
  • talc was added to the composition to increase stiffness of the end product. This increased the flexure modulus or bending resistance of the material to an applied load.
  • Other property enhancers or additives were added in varying compositions as shown in table 1. These enhancers impart color, improve UV resistance, scratch, and other properties of the material.
  • polypropylene composite was made into pellets, and these were tested for various properties such as rheological properties, thermal properties, physical properties, and electrical properties as shown below.
  • Test method ISO 17744 - 2004 Sample Conditioning: 24 °C for 48 hrs
  • Test method ASTM D 792 • Specimen Preparation method: Injection Molding
  • Table 4 Electrical values With a dissipation factor of 0.0275 @50Hz, the polypropylene housing was tested for RF performance and compared with existing housing using PC material. The results showed that there was no issue in antenna performance using polypropylene composite material.
  • compositions of the present disclosure are compared with the marketed product PC-ABS and provided in table 7.
  • Table 7 shows the comparison between PC-ABS material Vs PP. From comparing the results, it is apparent that the composition D (PP) of the present disclosure has low dielectric constant and low dissipation factor which helps to transmit antenna signals with significantly less attenuation. Additionally, the elongation at yield and break is higher for PP than PC-ABS, rendering the PP material more ductile. This property contributes to prevention of cracks in the device upon impact or dropping.
  • Composite Composition C has improved mechanical properties compared to Composite Composition A.
  • the tensile strength has increased from 19.2 to 21.3 and the Izod impact strength has gone up from 292.35 to 337. This is crucial for its intended application.
  • the HDT heat deflection temperature
  • the HDT has risen from 107.2 °C to 113°C, allowing the use of higher wattage components in electronic devices.

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  • Chemical & Material Sciences (AREA)
  • Crystallography & Structural Chemistry (AREA)
  • Health & Medical Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Medicinal Chemistry (AREA)
  • Polymers & Plastics (AREA)
  • Organic Chemistry (AREA)
  • Compositions Of Macromolecular Compounds (AREA)

Abstract

La présente invention concerne une composition composite de polypropylène. La composition composite de polypropylène comprend un mélange de copolymères chocs de polypropylène ; et éventuellement, un additif. La présente invention concerne également un article ou un composant produit par moulage de la composition composite de polypropylène.
PCT/IB2024/052543 2023-03-15 2024-03-15 Composition composite de polypropylène Ceased WO2024189596A1 (fr)

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IN202321013871 2023-03-15
IN202321013871 2023-03-15

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Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP2248853A1 (fr) * 2006-08-16 2010-11-10 Dow Global Technologies Inc. Matériau polymère et procédé pour le constituer et pour l'employer
WO2015044785A2 (fr) * 2013-09-27 2015-04-02 Basf Se Compositions de polyoléfines pour matériaux de construction
EP4192312A1 (fr) * 2020-08-05 2023-06-14 Berry Global, Inc. Feuilles et articles de polypropylène

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP2248853A1 (fr) * 2006-08-16 2010-11-10 Dow Global Technologies Inc. Matériau polymère et procédé pour le constituer et pour l'employer
WO2015044785A2 (fr) * 2013-09-27 2015-04-02 Basf Se Compositions de polyoléfines pour matériaux de construction
EP4192312A1 (fr) * 2020-08-05 2023-06-14 Berry Global, Inc. Feuilles et articles de polypropylène

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