Filled automotive polypropylene composition containing recyclates
Composition suitable for automotive application obtainable by blending at least components a) to f) a) 5.0 to 45 wt.-%, preferably 9.0 to 42 wt. %, more preferably 10 to 40 wt.-% of a first heterophasic polypropylene copolymer (HECO 1) b) 2.0 to 20 wt.-%, preferably 2.5 to 18 wt.-%, more preferably 3.0 to 17 wt.-% of a second heterophasic polypropylene copolymer (HECO 2) c) 10 to 60 wt.-%, preferably 12 to 55 wt.-%, more preferably 14 to 52 wt.-% of a polypropylene-polyethylene blend (A) d) 2.5 to 25 wt.-%, preferably 5.0 to 22 wt.-% and more preferably 6.5 to 20 wt.-% of an ethylene based elastomer e) 5.0 to 30 wt.-%, preferably 7.0 to 25 wt.-% and more preferably 8.5 to 20 wt.-% of an inorganic filler f) 0.1 to 4.0 wt.-% of additives.
1 . A composition suitable for automotive application obtainable by blending at least components a) to f),
a) 5.0 to 45 wt.-% of a first heterophasic polypropylene copolymer (HECO 1);
b) 2.0 to 20 wt.-% of a second heterophasic polypropylene copolymer (HECO 2);
c) 10 to 60 wt.-% of a polypropylene-polyethylene blend (A);
d) 2.5 to 25 wt.-% of an ethylene based elastomer;
e) 5.0 to 30 wt.-% of an inorganic filler;
f) 0.1 to 4.0 wt.-% of additives
wherein all percentages refer to the total composition, and wherein
(i) the first heterophasic polypropylene copolymer (HECO 1) comprises a matrix phase and an elastomer phase dispersed therein, the first heterophasic polypropylene copolymer (HECO 1) having:
a melt flow rate MFR2 (230° C., ISO1133) of 75 to 200 g/10 min; and
an intrinsic viscosity (measured in decalin according to DIN ISO 1628/1 at 135° C.) of 1.2 dl/g to 3.2 dl/g of the xylene cold soluble fraction (XCS); and
(ii) the second heterophasic polypropylene copolymer (HECO 2) comprises a matrix phase and an elastomer phase dispersed therein, the second heterophasic polypropylene copolymer (HECO 2) having:
a melt flow rate MFR2 (230° C., ISO1133) of 2.5 to 10 g/10 min; and
an intrinsic viscosity (measured in decalin according to DIN ISO 1628/1 at 135° C.) of 4.0 dl/g to 10 dl/g of the xylene cold soluble fraction (XCS); and wherein
(iii) the polypropylene-polyethylene blend (A) comprises
A-1) polypropylene,
A-2) polyethylene,
wherein the weight ratio of polypropylene to polyethylene is from 19:1 to 7:3, and the polypropylene-polyethylene blend (A) having:
a melt flow rate MFR2 (230° C., ISO1133) of 5.0 to 30 g/10 min; and
a xylene cold soluble fraction (XCS) of 2.0 to 15 wt.-% (ISO 16152, 1ed, 25° C.); and
wherein the polypropylene-polyethylene blend (A) has one or more of the following properties:
(aa) a content of limonene as determined by using solid phase microextraction (HS-SPME-GC-MS) of from 0.1 ppm to 100 ppm;
(bb) a content of fatty acid(s) as determined by using solid phase microextraction (HS-SPME-GC-MS) of 0.1 to 100 ppm;
and wherein
the ethylene based elastomer is selected from the group of C2C4 elastomers, C2C6 elastomers and/or C2C8 elastomers, and wherein the ethylene based elastomer
has a melt flow rate MFR2 (190° C., ISO1133) of 0.05 to 5.0 g/10 min, and
has a density of 850 to 885 kg/m 3 ; and wherein
(iv) the inorganic filler, preferably tale,
has a median particle size d 50 before compounding of 0.3 to 3.0 micrometers, and
wherein components a) to e) amount to at least 90 wt.-% of said composition suitable for automotive application.
2 . The composition suitable for automotive application according to claim 1 obtainable by blending at least components a) to f),
a) 5.0 to 45 wt.-% of the first heterophasic polypropylene copolymer (HECO 1),
b) 2.0 to 20 wt.-% of the second heterophasic polypropylene copolymer (HECO 2),
c) 10 to 60 wt.-% of the polypropylene-polyethylene blend (A),
d) 2.5 to 25 wt.-% of the ethylene based elastomer,
e) 5.0 to 30 wt.-% of the inorganic filler,
f) 0.1 to 4.0 wt.-% of additives,
wherein all percentages refer to the total composition, and wherein
(ee) the first heterophasic polypropylene copolymer (HECO 1) comprises a matrix phase and an elastomer phase dispersed therein, the first heterophasic polypropylene copolymer (HECO 1) having:
a melt flow rate MFR2 (230° C., ISO1133) of 75 to 200 g/10 min;
a xylene cold soluble fraction (XCS) of 8.0 to 20.0 wt.-% (ISO 16152, 1ed, 25° C.);
an intrinsic viscosity (measured in decalin according to DIN ISO 1628/1 at 135° C.) of 1.2 dl/g to 3.2 dl/g of the xylene cold soluble fraction (XCS); and
a melt flow rate MFR2 (230° C., ISO1133) of 100 to 500 g/10 min of the xylene insoluble (XCI) fraction (ISO 16152, 1ed, 25° C.),
a content of units derived from ethylene in the xylene cold soluble fraction (XCS) of 25.0 to 50.0 wt.-%
a total content of units derived from ethylene of 2.0 to 13.0 wt.-%, and wherein
(ff) the second heterophasic polypropylene copolymer (HECO 2) comprises a matrix phase and an elastomer phase dispersed therein, the second heterophasic polypropylene copolymer (HECO 2) having:
a melt flow rate MFR2 (230° C., ISO1133) of 2.5 to 10 g/10 min;
a xylene cold soluble fraction (XCS) of 20 to 50 wt.-%;
an intrinsic viscosity (measured in decalin according to DIN ISO 1628/1 at 135° C.) of 4.0 dl/g to 10 dl/g of the xylene cold soluble fraction (XCS);
a melt flow rate MFR2 (230° C., ISO1133) of 20 to 90 g/10 min of the xylene insoluble (XCI) fraction (ISO 16152, 1ed, 25° C.), and
a content of units derived from ethylene in the xylene cold soluble fraction (XCS) of 15.0 to 25.0 wt.-%,
a total content of units derived from ethylene of 3.0 to 15.0 wt.-%, and wherein
(gg) the polypropylene-polyethylene blend (A) comprises
A-1) polypropylene,
A-2) polyethylene,
wherein the weight ratio of polypropylene to polyethylene is from 19:1 to 7:3, and the polypropylene-polyethylene blend (A) having
a melt flow rate MFR2 (230° C., ISO1133) of 5.0 to 30 g/10 min;
a xylene cold soluble fraction (XCS) of 2.0 to 15 wt.-% (ISO 16152, 1ed, 25° C.); and
wherein the polypropylene-polyethylene blend (A) has one or more of the following properties:
(aa) a content of limonene as determined by using solid phase microextraction (HS-SPME-GC-MS) of from 0.1 ppm to 100 ppm;
(bb) a content of fatty acid(s) as determined by using solid phase microextraction (HS-SPME-GC-MS) of 0.1 to 100 ppm;
(cc) a content of polyamide(s) as determined by NMR of 0.05 to 1.5 wt.-%;
(dd) a content of polystyrene(s) as determined by NMR of 0.05 to 3.0 wt.-%; and
wherein
the ethylene based elastomer is selected from the group of C2C4 elastomers, C2C6 elastomers and/or C2C8 elastomers, the ethylene based elastomer
having a melt flow rate MFR2 (190° C., ISO1133) of 0.05 to 5.0 g/10 min, and
having a density of 850 to 885 kg/m 3 ; and wherein
(ee) the inorganic filler,
has a median particle size d 50 before compounding of 0.3 to 3.0 micrometers; and
wherein components a) to e) amount to at least 90 wt.-% of said composition suitable for automotive application.
3 . The composition suitable for automotive application according to claim 1 having tensile modulus (ISO 527.2; 23° C.) of 1300 to 1700 MPa.
4 . The composition suitable for automotive application according to claim 1 , obtainable by blending at least components a) to f),
a) 20 to 35 wt.-% of the first heterophasic polypropylene copolymer (HECO 1);
b) 5.0 to 20 wt.-% of the second heterophasic polypropylene copolymer (HECO 2);
c) 20 to 30 wt.-% of the polypropylene-polyethylene blend (A);
d) 7.0 to 22 wt.-% of the ethylene based elastomer;
e) 5.0 to 25 wt.-% of the inorganic filler;
f) 0.1 to 4.0 wt.-% of additives.
5 . The composition suitable for automotive application according to claim 4 having a tensile modulus (ISO 527.2; 23° C.) of 1400 to 1700 MPa,
and
having a Charpy notched impact strength of at least 40 kJ/m 2 (1eA) (non-instrumented, ISO 179-1 at +23° C.).
6 . The composition suitable for automotive application according to claim 4 having a heat deflection temperature (ISO 75 B) of at least 90° C.
7 . The composition suitable for automotive application according to claim 1 having a melt flow rate (ISO 1133, 2.16 kg, 230° C.) of 10.0 to 25 g/10 min.
8 . The composition suitable for automotive application according to claim 1 , obtainable by blending at least components a) to f),
a) 5.0 to 20 wt.-% of the first heterophasic polypropylene copolymer (HECO 1);
b) 2.5 to 7.0 wt.-% of the second heterophasic polypropylene copolymer (HECO 2);
c) 30 to 55 wt.-% of the polypropylene-polyethylene blend (A);
d) 7.0 to 22 wt.-% of the ethylene based elastomer;
e) 5.0 to 25 wt.-% of the inorganic filler;
f) 0.1 to 4.0 wt.-% of additives.
9 . The composition suitable for automotive application according to claim 8
having a tensile modulus (ISO 527.2; 23° C.) of 1200 to 1400 MPa,
and
having a Charpy notched impact strength of at least 40 KJ/m 2 (1eA) (non-instrumented, ISO 179-1 at +23° C.).
10 . The composition suitable for automotive application according to claim 8 having a melt flow rate (ISO 1133, 2.16 kg, 230° C.) of 6.0 to 15 g/10 min.
11 . The composition suitable for automotive application according to claim 1 , wherein the additives are selected from one or more of antioxidant(s), UV stabilizer(s), slip agent(s), nucleating agent(s), pigment(s), lubricant(s), masterbatch polymer(s) and anti-fogging agents.
12 . The composition suitable for automotive application according to claim 1 having a VOC as measured on the material as obtained directly from the extrusion following the procedure as described in VDA278 of less than 75 mg per gram of composition.
13 . The composition suitable for automotive application according to claim 1 having a paint adhesion assessed as the failed or delaminated coated area in mm 2 of below 24 mm 2 .
14 . An article comprising the composition according to claim 1 .
15 . The composition according to claim 1 , wherein the polypropylene-polyethylene based (A) has a residual ash content of below 3.0 wt.-%.
16 . The composition according to claim 1 , wherein the inorganic filler is talc.
17 . The composition according to claim 1 , wherein the inorganic filler has a top cut particle size D 95 before compounding of 1.0 to 8.0 micrometers.
18 . The composition according to claim 1 , obtainable by blending at least components a) to f),
a) 20 to 35 wt.-% of the first heterophasic polypropylene copolymer (HECO 1);
b) 5.0 to 20 wt.-% of the second heterophasic polypropylene copolymer (HECO 2);
c) 20 to 30 wt.-% of the polypropylene-polyethylene blend (A);
d) 11.0 to 20 wt.-% of the ethylene based elastomer;
e) 7.0 to 19 wt.-% of the inorganic filler;
f) 0.1 to 4.0 wt.-% of additives.
19 . The composition according to claim 1 , obtainable by blending at least components a) to f),
a) 5.0 to 20 wt.-% of the first heterophasic polypropylene copolymer (HECO 1);
b) 2.5 to 7.0 wt.-% of the second heterophasic polypropylene copolymer HECO 2);
c) 30 to 55 wt.-% of the polypropylene-polyethylene blend (A);
d) 11.0 to 22 wt.-% of the ethylene based elastomer;
e) 7.0 to 20 wt.-% of the inorganic filler;
f) 0.1 to 4.0 wt.-% of additives.