Thermoplastic polymer and novolac composition and method
Compositions comprising a novolac polymer, an olefin-based polymer with an epoxy group, a filler and optionally a thermoplastic polymer are provided. The compositions may be halogen-free. The present compositions exhibit excellent compatibility between the novolac polymer and the olefin-based polymer with an epoxy group resulting in compositions with superior mechanical properties.
1. A composition comprising:
about 15 wt % to about 30 wt % of a novolac polymer;
about 0.1 wt % to about 10 wt % of an olefin-based polymer with an epoxy group; and
greater than 0 wt % to about 70 wt % of a filler.
2. The composition of claim 1 further comprising a thermoplastic polymer.
3. The composition of claim 2 comprising greater than 0 wt % to about 99 wt % thermoplastic polymer.
4. The composition of claim 3 wherein the thermoplastic polymer is an olefin-based polymer.
5. The composition of claim 3 wherein the novolac polymer is a phenol novolac polymer.
6. The composition of claim 3 wherein the olefin-based polymer with an epoxy group comprises an unsaturated glycidyl ester.
7. The composition of claim 3 comprising an additional component selected from the group consisting of a flame retardant, an anti-drip agent, a functionalized polyolefin, a processing additive, an elastomeric composition, a dispersed polymer, and combinations thereof.
8. The composition of claim 3 wherein the olefin-based polymer with an epoxy group comprises an ethylene/glycidyl methacrylate copolymer and the thermoplastic polymer is selected from the group consisting of an ethylene/α-olefin copolymer, an olefin block ethylene/α-olefin copolymer, and combinations thereof.
9. The composition of claim 3 comprising:
a continuous phase comprising the olefin-based polymer with an epoxy group;
a discontinuous phase comprising the novolac polymer dispersed in the continuous phase; and
a filler.
10. The composition of claim 9 wherein the continuous phase comprises the olefin-based polymer with an epoxy group and a thermoplastic polymer.
11. The composition of claim 10 comprising greater than about 50 wt % to about 99 wt % of the continuous phase and from about 1 wt % to about less than 50 wt % of the discontinuous phase.
12. The composition of claim 11 wherein thermoplastic polymer is selected from the group consisting an ethylene/α-olefin copolymer, an olefin block ethylene/α-olefin copolymer, and combinations thereof.
13. The composition of claim 9 wherein the discontinuous phase comprises a phenol novolac polymer.
14. The composition of claim 9 wherein the discontinuous phase has a domain size less than about 10 μm.
15. The composition of claim 9 wherein the olefin-based polymer with an epoxy group comprises an unsaturated glycidyl ester.
16. The composition of claim 9 comprising a component selected from the group consisting of a flame retardant, an anti-drip agent, a functionalized polyolefin, a processing additive, an elastomeric composition, a dispersed polymer, and combinations thereof.
17. An article comprising at least one component formed from the composition of claim 1 .
18. A process for producing a heterophasic composition comprising:
blending a novolac polymer, a filler, an olefin-based polymer with an epoxy group, and optionally a thermoplastic polymer; and
forming a heterophasic composition.
19. The process of claim 18 comprising forming a discontinuous phase comprising novolac polymer domains of less than about 10 μm in a continuous phase comprising the olefin-based polymer with an epoxy group and optionally the thermoplastic polymer.
20. An article comprising at least one component formed from the composition of claim 9 .