Thermoplastic articles and processes for making the same using an improved masterbatch

1. A process for making a shaped article, comprising the steps of:

a) providing as separate materials a first material that includes a first polyolefin, and a second material including an admixture of:

(i) from about 45 to 85 wt. % of the total admixture of at least one particulated mineral filler; and

(ii) from about 15 to 55 wt. % of the total admixture of at least a second polyolefin wherein the second polyolefin comprises a polyolefin plastomer that includes a thermoplastic having a primary monomer of ethylene, a comonomer selected from the group consisting of 1-butene, 1-hexene, and 1-octene, and is characterized by a melt index greater than 150 g/10 min at 190° C./2.16 kg, as measured per ISO 1133 (condition D);

b) applying a shear force to the first and second materials, while the materials are at an elevated temperature for blending the materials to form a molten blend;

c) shaping the molten blend; and

d) solidifying the molten blend; wherein

the step of applying a shear force occurs while the first and second materials advance along a screw within a screw and barrel assembly, and

the process is substantially free of a step of compounding together the first and second materials prior to introducing the first and second materials to the screw and barrel assembly.

2. The process of claim 1 , wherein

the first polyolefin of the first material comprises a thermoplastic polyolefin,

the polyolefin plastomer includes a polymer made with a metallocene catalyst; and

the second material further comprises a propylene-ethylene copolymer characterized by

i) a melt index greater than about 10 g/10 min at 230° C./2.16 kg as measured per ISO 1133 (condition M), and

ii) a flexural modulus of less than about 100 MPa, as measured per ASTM D-790A.

3. The process of claim 2 , wherein the process is substantially free of a step of compounding together the first, second and any optional other materials prior to the blending step.

4. The process of claim 3 , further comprising a step of providing a color concentrate for achieving a desired color in the resulting shaped article.

5. The process of claim 2 , further comprising a step of providing regrind for blending with at least the first and second materials.

6. The process of claim 2 , wherein the step of shaping the molten blend includes injection molding the molten blend into a cavity of a molding tool.

7. A process for making a shaped article, comprising the steps of:

a) providing as separate materials a first material that includes a first polyolefin, and a second material including an admixture of:

(i) from about 45 to 85 wt. % of the total admixture of at least one particulated mineral filler; and

(ii) from about 15 to 55 wt. % of the total admixture of at least a second polyolefin wherein the second polyolefin comprises a polyolefin plastomer that includes a thermoplastic having a primary monomer of ethylene, a comonomer selected from the group consisting of 1-butene, 1-hexene, and 1-octene, and is characterized by a melt index greater than 150 g/10 min at 190° C./2.16 kg, as measured per ISO 1133 (condition D);

b) applying a shear force to the first and second materials, while the materials are at an elevated temperature for blending the materials to form a molten blend;

c) shaping the molten blend; and

d) solidifying the molten blend; wherein

the step of applying a shear force occurs while the first and second materials advance along a screw within a screw and barrel assembly;

the process is substantially free of a step of compounding together the first and second materials prior to introducing the first and second materials to the screw and barrel assembly;

the first polyolefin of the first material comprises a thermoplastic polyolefin;

the polyolefin plastomer includes a polymer made with a metallocene catalyst;

the second material further comprises a propylene-ethylene copolymer characterized by a melt index greater than 10 g/10 min at 230° C./2.16 kg as measured per ISO 1133 (condition M) and a flexural modulus of less than 100 MPa, as measured per ASTM D-790A; and

the thermoplastic polyolefin of the first material includes a polypropylene impact copolymer characterized by a melt flow rate of less than 70 g/10 min (ISO 1133 condition M at 230° C., 2.16 kg), containing greater than 8 wt % (of the first material) of ethylene, having greater than about 40% crystallinity, or any combination thereof.

8. The process of claim 2 , wherein the providing step includes dry blending the first and second materials.

9. The process of claim 2 , wherein at least the first and the second materials are provided as pellets.

10. The process of claim 9 , wherein at least 50% by weight of both of the pellets of the first material and the pellets of the second material are substantially the same volume.

11. The process of claim 10 , further comprising admixing with the first material and the second material at least one additive selected from a heat stabilizer, a UV stabilizer, a mold release agent, a nucleator, a lubricant, a slip agent, a colorant or any combination thereof.

12. The process of claim 2 , wherein the particulated mineral filler is talc.

13. The process of claim 2 , wherein the particulated mineral filler is present in an amount of about 70% by weight the total admixture.

14. The process of claim 12 , wherein the second polyolefin includes an ethylene-octene copolymer.

15. The process of claim 14 , wherein the first polyolefin includes greater than 8 wt % (by weight of the first material) of ethylene.

16. The process of claim 15 , wherein the median particle diameter of the talc is less than 3 microns.

17. The process of claim 16 , wherein the average volume of the particles of the second material is larger than the average volume of the particle size of the first material.

18. The process of claim 1 , wherein the second polyolefin is compatible with an elastomeric component of the first polyolefin.

19. The process of any of claim 2 , wherein particles of the second material are coated or partially coated with a mineral filler or a micronized polymer.

20. The process of claim 2 , wherein the propylene-ethylene copolymer is characterized by:

i) from 6% by weight to 25% by weight ethylene-derived units, and from 75% by weight to 94% by weight propylene-derived units, the percentages by weight based on the total weight of propylene- and ethylene-derived units, and

ii) a melting point ranging from 35° C. to 110° C.

21. The process of claim 1 , wherein the polyolefin plastomer includes a metallocene catalyzed ethylene α-olefin copolymer having a density in the range of 0.910 to 0.860 g/cm3, and the ethylene α-olefin copolymer is based on butene, hexane, or octene copolymer.

22. A process for making a shaped article, comprising the steps of:

a) providing as separate materials:

a first material that includes a polypropylene impact copolymer characterized by a melt flow rate of less than 70 g/10 min (ISO 1133 condition M at 230° C., 2.16 kg), containing greater than 8 wt % (of the first material) of ethylene, having greater than 40% crystallinity, or any combination thereof; and

and a second material including an admixture of:

(i) from 45 to 85 wt. % of the total admixture of at least one particulated mineral filler; and

(ii) from 15 to 55 wt. % of the total admixture of at least a second polyolefin wherein the second polyolefin comprises a polyolefin plastomer that includes a thermoplastic having a primary monomer of ethylene, a comonomer selected from the group consisting of 1-butene, 1-hexene, and 1-octene, and is characterized by a melt index greater than 150 g/10 min at 190° C./2.16 kg, as measured per ISO 1133 (condition D);

b) applying a shear force to the first and second materials, while the materials are at an elevated temperature for blending the materials to form a molten blend;

c) shaping the molten blend; and

d) solidifying the molten blend; wherein

the step of applying a shear force occurs while the first and second materials advance along a screw within a screw and barrel assembly, and

the process is substantially free of a step of compounding together the first and second materials prior to introducing the first and second materials to the screw and barrel assembly.