Calendered films of plasticized blends of plastomer and impact copolymer

1. A film having a thickness of from 0.5 to 35 mils (12.7 to 889 microns) comprising a blend composition comprising:

a) 4 to 50 wt %, based upon the weight of the composition, of one or more polypropylene-based TPO(s) comprising at least 50 wt % propylene and at least 10 wt % ethylene having a melt flow rate (MFR) of 7 dg/min or less, a Tm of 150° C. or more, and a lowest Tg of −30° C. or less; and

b) 30 to 80 wt %, based upon the weight of the composition, of one or more ethylene plastomer(s) having a melt index of 3 dg/min or less and a density of 0.869 to 0.910 g/cc; and

c) 0.5 to 35 wt %, based upon the weight of the composition, of one or more non-functionalized plasticizer(s) having a kinematic viscosity at 100° C. of 4 to 300 cSt, a pour point of −20° C. or less, and a flash point of 200° C. or more; and

d) 0 to 69.5 wt %, based upon the weight of the composition, of one or more filler(s);

said blend composition having:

i) a tensile strength of 7 MPa or more, and

ii) an elongation at break in the machine and transverse directions of 400% or more, and

iii) a flexural modulus of 50 MPa or less, and

iv) Vicat softening point of 50° C. or more, and

v) a highest Tm of 145° C. or more, and

vi) a Roll Change Point of 5 to less than 29 mils (127 to 737 microns); and

wherein the blend composition is calendered into a film having a thickness of 0.5 to 35 mils (12.7 to 889 microns).

2. The film or sheet of claim 1 , wherein the blend composition has two melting points as measured by DSC, the first being at least 145° C. and the second being at least 40° C., where the two Tm's are at least 20° C. apart.

3. The film or sheet of claim 1 , wherein the blend composition has a Tear Strength of 45 kg/cm or more.

4. The film or sheet of claim 1 , wherein the blend composition has an equal or better scratch resistance rating as compared to the same blend composition without NFP.

5. The film or sheet of claim 1 , wherein the blend composition has a scratch resistance rating of 3 N or more.

6. The film or sheet of claim 1 , wherein the filler is an inorganic mineral filler with a median particle diameter of 0.1 to 100 microns and or an aspect ratio of greater than 1.2.

7. The film or sheet of claim 1 , wherein the filler is selected from the group consisting of mineral aggregates, fibers, carbon black, graphite, wollastonite, clays, sand, and glass beads.

8. The film or sheet of claim 1 , wherein the polypropylene-based TPO comprises a matrix having a T m of 110° C. or more and a dispersed phase having a T g of −20° C. or less.

9. The film or sheet of claim 1 , wherein the propylene based TPO is one or more in-situ ICP(s).

10. The film or sheet of claim 1 , wherein the ethylene plastomer has an ethylene content of 60 to 96 wt %.

11. The film or sheet of claim 1 , wherein the ethylene plastomer has a density of 0.91 to 0.86 g/cm 3 .

12. The film or sheet of claim 1 , wherein the NFP is a polyalphaolefin.

13. The film or sheet of claim 1 , wherein the NFP is a mixture of C 20 to C 120 paraffins, 50 wt % or more being isoparaffinic hydrocarbons and less than 50 wt % being hydrocarbons that contain naphthenic and/or aromatic structures.

14. The film or sheet of claim 1 , wherein the filler is a flame retardant filler.

15. The film or sheet of claim 1 , wherein the polypropylene-based TPO is present at 6 to 20 wt % and has a melting point, Tm, of 155° C. or more; the ethylene based plastomer is present at 40 to 70 wt % and has a density of 0.862 to 0.87 g/cc; the non-functionalized plasticizer(s) is present at 0.5 to 15 wt % and has a viscosity index of 100 or more and a specific gravity of 0.88 or less; and the filler is present at 5 to 20 wt %.

16. A process to make a film or sheet having a thickness of from 0.5 to 35 mils (12.7 to 889 microns) comprising:

1) combining:

a) 4 to 50 wt %, based upon the weight of the composition, of a polypropylene-based TPO comprising at least 50 wt % propylene and at least 10 wt % ethylene, having an MFR of 10 dg/min or less, a Tm of 150° C. or more, and a lowest Tg of −30° C. or less; and

b) 30 to 80 wt %, based upon the weight of the composition, of an ethylene plastomer having a melt index of 3 dg/min or less and a density of 0.860 to 0.91 g/cc; and

c) 0.25 to 35 wt %, based upon the weight of the composition, of one or more non-functionalized plasticizer(s) having a kinematic viscosity at 100° C. of 4 to 300 cSt, a pour point of −20° C. or less, and a flash point of 200° C. or more; and

d) 0 to 69.5 wt %, based upon the weight of the composition, of one or more filler(s); to form a blend; and

2) calendering the blend between at least two calendering rolls at a temperature of 80° C. to 220° C., said rolls having a nip distance of about 1 to about 50 mils (25.4 to 1270 microns) where the blend has:

i) a tensile strength (Machine Direction) of 7 MPa or more; and

ii) an elongation at break (Transverse and/or Machine Direction) of 400% or more; and

iii) a flexural modulus of 50 MPa or less; and

iv) a Vicat softening temperature of 50° C. or more; and

v) a highest Tm of 145° C. or more; and

vi) a Roll Change Point of 5 to less than 29 mils (127 to 737 microns); and

3) wherein the blend composition is calendered into a film or sheet having a thickness of 0.5 to 35 mils (12.7 to 889 microns).

17. The process of claim 16 , wherein the friction ration between the first and second rolls in the calender is about 1.0 to about 2.0.

18. The process of claim 16 , wherein the blend has a Roll Change Point of 10 to 25 mils (254 to 635 microns).

19. The process of claim 16 , wherein the blend has a Roll Change Point of 15 to 22 mils (381 to 559 microns).

20. The process of claim 16 , wherein the blend is calendered into a film or sheet having a thickness of 2 to 30 mils (51 to 762 microns).

21. The process of claim 16 , wherein the blend is calendered into a film or sheet having a thickness of 20 to 25 mils (508 to 635 microns).

22. The process of claim 16 , wherein the blend composition has two melting points as measured by DSC, the first being at least 145° C. and the second being at least 40° C., where the two Tm's are at least 20° C. apart and the blend composition has a Tear Strength of 45 kg/cm or more.

23. The process of claim 16 , wherein the blend composition has an equal or better scratch resistance rating as compared to the same blend composition without NFP.

24. The process of claim 16 , wherein the blend composition has a scratch resistance rating of 3 N or more.

25. The process of claim 16 , wherein the polypropylene-based TPO is an in-situ TPO, is present at 6 to 20 wt % and has a Tm of 155° C. or more; the ethylene based plastomer is present at 40 to 70 wt % and has a density of 0.862 to 0.87 g/cc; the non-functionalized plasticizer(s) is present at 0.5 to 15 wt % and has a viscosity index of 100 or more and a specific gravity of 0.88 or less; and the filler is present at 5 to 20 wt %.