Articles with high rigidity and low warpage comprising heterophasic propylene polymer composition and uses therefor

1 . An article comprising a polypropylene composition comprising

a heterophasic propylene copolymer which comprises:

a) a matrix phase (A) comprising at least one propylene homopolymer and/or a propylene copolymer, and

b) a disperse phase (B) comprising a propylene copolymer rubber dispersed in the matrix phase (A), wherein

the propylene copolymer rubber of the disperse phase (B) has a comonomer content of 30 to 55 wt. %,

wherein the weight ratio of the matrix phase (A) and the disperse phase (B) is from 20:80 to 80:20;

wherein an intrinsic viscosity (IV) of a xylene cold solubles fraction (XCS) of the heterophasic propylene copolymer is from 2.0 to 4.5 dl/g; and

the polypropylene composition has:

(i) a melt flow rate MFR2 of 1 g/10 min to 500 g/10 min, determined according to ISO 1133 (230° C., 2.16 kg load); and

the article has:

(ii) a half-time of crystallisation t1/2 of 1 to 20 msec, measured at 80° C. by fast scanning calorimeter as described in the specification.

2 . The article according to claim 1 , wherein the comonomer of the propylene copolymer rubber of the disperse phase (B) of the heterophasic propylene copolymer is an ethylene or a C4 to C10 alpha-olefin or any combination thereof.

3 . The article according to claim 1 , wherein the total comonomer content of the heterophasic propylene copolymer is from 2.5 to 15.0 wt. %, determined by FTIR calibrated with 13C-NMR.

4 . The article according to claim 1 , wherein the propylene copolymer rubber of the disperse phase (B) of the heterophasic propylene copolymer is a unimodal or bimodal composition.

5 . The article according to claim 1 , wherein the heterophasic propylene copolymer is nucleated with a nucleating agent, wherein the nucleating agent optionally is a polymeric vinyl alkane.

6 . The article according to claim 1 , wherein the amount of xylene cold solubles (XCS) of the heterophasic propylene copolymer is in the range of from 10 to 30 wt. %, determined according to ISO 16152:2005.

7 . The article according to claim 1 , wherein the heterophasic propylene copolymer has a melting temperature (Tm) in the range of from 161 to 167° C. and/or a crystallization temperature (Tc) of greater than 125° C., Tm and Tc being measured by differential scanning calorimetry (DSC).

8 . The article according to claim 1 , which has a tensile modulus, determined according to ISO 527-2:2012-06 (cross head speed: 1 mm/min.), in the range of from 1200 to 2200 MPa.

9 . The article according to claim 1 , which has a Charpy notched impact strength at 23° C., determined according to ISO 179 1 eA, of 5.5 to 15.0 kJ/m2.

10 . A process for preparing a polypropylene composition as defined in claim 1 , comprising the following stages (i) and (ii) in any sequence:

(i) preparation of the matrix phase of the heterophasic propylene copolymer of the polypropylene composition, wherein stage (i) comprises the following steps:

B2) polymerisation of propylene to afford a propylene homopolymer, or the co-polymerisation of propylene with an alpha-olefin comonomer to result in a propylene copolymer, step B2 being conducted in at least one slurry phase reactor, and optionally

B3) polymerisation of propylene to afford a propylene homopolymer, or the co-polymerisation of propylene with an alpha-olefin comonomer to result in a propylene copolymer, step B3 being conducted in at least one gas phase reactor,

(ii) preparation of the disperse phase of the heterophasic propylene copolymer of the polypropylene composition, wherein stage (ii) comprises the following step:

B4) co-polymerisation of propylene with an alpha-olefin comonomer to result in an olefin-propylene copolymer, step B4 being conducted in at least one gas phase reactor, and wherein:

a) the process B2 is conducted at a reactor temperature of between 7° and 110° C.,

b) the process B3 is conducted at a reactor temperature of between 7° and 110° C., and

c) the process B4 is conducted at a reactor temperature of between 7° and 110° C.

11 . The process according to claim 10 , wherein the polypropylene composition has been polymerised in the presence of

a) a Ziegler-Natta catalyst (ZN-C) comprising compounds (TC) of a transition metal of Group 4 to 6 of the IUPAC Periodic Table of Elements, a Group 2 metal compound (MC) and an internal donor (ID), wherein said internal donor (ID) is a non-phthalic compound,

b) a co-catalyst (Co), and

c) optionally an external donor (ED).

12 . The process according to claim 10 , wherein the internal donor (ID) is selected from the group consisting of optionally substituted malonates, maleates, succinates, glutarates, cyclohexene-1,2-dicarboxylates, benzoates and derivatives and/or mixtures thereof.

13 . The process according to claim 10 , wherein after step B4, stage (ii) further comprises a step B5):

B5) co-polymerisation of propylene with an alpha-olefin comonomer to result in an olefin-propylene copolymer.

14 . A method for producing an article, comprising molding the polypropylene composition as defined in claim 1 , to produce the article.

15 . The method of claim 14 , wherein the article is a thin wall molded article.

16 . The method of claim 14 , wherein the molding is injection molding.

17 . The article according to claim 5 , wherein the nucleating agent is a polymeric vinyl cycloalkane in which the monomeric unit is selected from the group consisting of vinyl cyclohexane, vinyl cyclopentane, vinyl-2-methyl-cyclohexane, and a mixture thereof.