# Patent

## Title
Polypropylene composition and molded article of the same

## Abstract

The present invention relates to a polypropylene composition containing: 100 parts by weight of a blending mixture containing 35 to 45% by weight of a polypropylene copolymer having an ethylene content of 4 to 20% by weight, 7 to 12% by weight of high-density polyethylene, 40 to 50% by weight of an ethylene-α-olefin copolymer rubber, and 5 to 10% by weight of a compatibilizer, and 0.05 to 0.1 parts by weight of a flow adjuster.

## Background
TECHNICAL FIELD
The present invention relates to a polypropylene composition mainly composed of polypropylene copolymer and having excellent low-temperature impact resistance while maintaining rigidity, and a molded article thereof.
BACKGROUND ART
Polypropylene (PP) compositions mainly composed of polypropylene, in which ethylene-propylene-based rubbers, inorganic fillers and the like are blended, have excellent rigidity and impact resistance and have high moldability, and therefore have been widely used for interior and exterior parts of automobiles or the like. They have also been used for air-bag pads (hereinafter also referred to as AB pads) of automobiles, and characteristics such as fluidity and impact resistance at low temperature are required therefor. In the polypropylene compositions, however, it is generally difficult to achieve both of the rigidity and the low-temperature impact resistance at the same time, and under the present circumstances, one of the characteristics cannot help being sacrificed to some extent.
In Patent Document 1, there is disclosed a polypropylene composition having a structure comprising polypropylene as a matrix phase and an elastomer as a dispersion phase, in which polyethylene is present in the dispersion phase, in order to obtain a balance between the rigidity and the low-temperature impact resistance. However, this compounding system is difficult to be applicable to a molded article particularly requiring fluidity (for example, an AB pad required to have a thick portion and a thin portion).
In Patent Document 2, there is disclosed a composition comprising PP composition comprising polypropylene, low-density polyethylene, an ethylene-olefin copolymer rubber and the like, and a peroxide blended in the PP composition in a predetermined amount, as a material for an AB pad having a thick portion and a thin portion. However, this compounding system is difficult to achieve a balance between the rigidity and the low-temperature impact resistance.

    Patent Document 1: JP-A-11-130923
    Patent Document 2: JP-A-2001-62861


SUMMARY OF THE INVENTION
Accordingly, an object of the present invention is to provide a polypropylene composition having high fluidity and excellent low-temperature impact resistance while maintaining rigidity, and a molded article thereof.
The present invention provides a polypropylene composition comprising:
100 parts by weight of a blending mixture comprising 35 to 45% by weight of a polypropylene copolymer having an ethylene content of 4 to 20% by weight, 7 to 12% by weight of high-density polyethylene, 40 to 50% by weight of an ethylene-α-olefin copolymer rubber, and 5 to 10% by weight of a compatibilizer, and
0.05 to 0.1 parts by weight of a flow adjuster.
Further, the present invention provides a molded article of the above polypropylene composition.


DETAILED DESCRIPTION OF THE INVENTION
Embodiments of the respective elements in the present invention will be exemplified below.
1. Polypropylene Copolymer
Polypropylene copolymer is a polypropylene block copolymer containing 4 to 20% by weight of ethylene. When the ethylene content is less than 4% by weight, there is a concern that impact strength is decreased or a flow mark caused by deterioration in rubber dispersibility is generated. On the other hand, when the ethylene content exceeds 20% by weight, there is a concern that deterioration in heat resistance or rigidity occurs.
2. High-Density Polyethylene
High-density polyethylene is preferably a polyethylene having a density of 0.96 g/cm3 or more, more preferably, from 0.96 g/cm3 to 0.98 g/cm3. The rigidity of the polypropylene composition can be maintained, and further, the low-temperature impact resistance thereof can also be secured by dispersing the high-density polyethylene in a rubber to reinforce the rubber. When the density is less than 0.96 g/cm3, it becomes difficult to achieve the above effects.
3. Ethylene-α-Olefin Copolymer Rubber
Examples of the α-olefins include propylene, butene, pentene and the like. However, an ethylene-butene copolymer rubber is preferable. This largely contributes to the low-temperature impact resistance.
4. Compatibilizer
Examples of the compatibilizer include a propylene-butene copolymer and an ethylene-propylene copolymer, and the propylene-butene copolymer is preferable. The compatibilizer enhances compatibility between polypropylene copolymer and rubber, and enhances tensile elongation of the rubber.
5. Flow Adjuster
Examples of the flow adjusters include ketone peroxides, peroxyketals, hydroperoxides, dialkyl peroxides, diacyl peroxides, peroxydicarbonates, peroxyesters and the like. However, dialkyl peroxides are preferable.
The fluidity of the polypropylene composition is improved by blending the flow adjuster, because molecular chain of polypropylene copolymer or rubber is broken.
6. Blending Amount
The above described polypropylene copolymer, high-density polyethylene, ethylene-α-olefin copolymer rubber, compatibilizer and flow adjuster are properly blended in such amounts that excellent low-temperature impact resistance can be secured while maintaining rigidity. For example, the polypropylene composition of the present invention comprises a blending mixture comprising 35 to 45% by weight of the polypropylene copolymer, 7 to 12% by weight of the high-density polyethylene, 40 to 50% by weight of the ethylene-α-olefin copolymer rubber, and 5 to 10% by weight of the compatibilizer, and further comprises the flow adjuster in an amount of 0.05 to 0.1 parts by weight based on 100 parts by weight of the blending mixture. The polypropylene composition of the present invention may contain other components such as stabilizer, to the extent that they do not impair the effect of the present invention. Examples of the other components includes phenolic antioxidant, amine thermal stabilizer, sulfur thermal stabilizer, phosphate thermal stabilizer, hindered amine light stabilizer, benzoate ultraviolet absorber, benzotriazole ultraviolet absorber, benzophenone ultraviolet absorber, triazine ultraviolet absorber.
Uses
The polypropylene composition of the present invention can be subjected to a known molding treatment such as injection molding, to provide a molded article. As the molded articles of the present invention, there can be exemplified automobile parts such as instrument panels, console boxes and side moldings, as well as the AB pads.
The present invention can provide a polypropylene composition having high fluidity and excellent low-temperature impact resistance while maintaining rigidity, and a molded article thereof.
EXAMPLES
Three kinds of samples for Examples and three kinds of samples for Comparative Examples were prepared by injection molding, by changing the blending amounts of respective components as shown in Table 1.
Physical property evaluation items are melt flow rate (MFR), Izod impact strength, tensile strength and elongation, and bending strength and elastic modulus.
Measurement methods of respective physical property tests will be described below.
The MFR was measured in accordance with ISO 1133 (measurement temperature: 230° C.).
The Izod impact strength (with notch) was measured in accordance with ISO 180 (measurement temperatures: 23° C. and −45° C.).
The tensile strength and elongation were measured in accordance with ISO 527.
The bending strength and elastic modulus were measured in accordance with ISO 178.
The results of physical property evaluation are shown in Table 1. The samples of Examples show high fluidity and excellent impact resistance even at low temperature while securing the bending elastic modulus. On the other hand, the samples of Comparative Examples 1 and 2 are decreased in the blending amount of high-density polyethylene, so that the impact resistance at low temperature is deteriorated. Further, the sample of Comparative Example 3 contains no compatibilizer, so that the tensile elongation is decreased.














TABLE 1







Ex. 1
Ex. 2
Ex. 3
Comp. Ex. 1
Comp. Ex. 2
Comp. Ex. 3
























Blending
Polypropylene
Ethylene Content:
40
40
40
45
50
40



Copolymer
10.6 wt %



High-Density
Density:
10
10
10
5
0
10



Polyethylene
0.967 g/cm3



Rubber
Ethylene-Butene
40
40
45
40
40
50




Rubber



Compatibilizer
Propylene-Butene
10
10
5
10
10
0




Copolymer



Flow Adjuster
Dibutyl Peroxide
0.05
0.1
0.05
0.05
0.05
0.05



Others
Stabilizer, etc.
0.7
0.7
0.7
0.7
0.7
0.7


Physical
MFR (g/10 min)
230° C.
8.29
9.78
7.42
9.76
9.18
4.65


Properties
Izod Impact Strength
 23° C.
53.7
51.2
45.6
49.5
49.4
47.3



with Notch (KJ/m2)
−45° C.
75.1
81.8
91.2
18.3
20.6
95.7

















Tensile
Mpa
Yield Strength
12.0
11.3
10.0
11.6
12.3
8.8





Breaking Strength
>11.6
>11.1
>9.5
>10.9
>11.5
7.9




%
Breaking
>510
>500
>567
>557
>540
128





Elongation



Bending
Mpa
Strength
10.7
10.3
9.2
11.3
11.9
8.3





Elastic Modulus
322
319
298
358
388
293










While the present invention has been described in detail with reference to the specific embodiments thereof, it will be apparent to one skilled in the art that various changes and modifications can be made therein without departing from the spirit and scope of the present invention.
The present application is based on the Japanese Patent Application No. 2012-075895 filed on Mar. 29, 2012, and the entire contents thereof are incorporated herein by reference. All references cited herein are incorporated in their entirety.

## Claims

1. A polypropylene composition comprising:
a blended mixture in an amount of 100 parts by weight, the blended mixture comprising:
35 to 45% by weight of a polypropylene copolymer having an ethylene content of 4 to 20% by weight,
7 to 12% by weight of high-density polyethylene having a density of 0.96 g/cm3 or more,
40 to 50% by weight of an ethylene-α-olefin copolymer rubber, and
5 to 10% by weight of a compatibilizer, and

a flow adjuster in an amount of 0.05 to 0.1 parts by weight.

2. The polypropylene composition according to claim 1, wherein the ethylene-α-olefin copolymer contains an α-olefin selected from the group consisting of propylene, butene and pentene.

3. The polypropylene composition according to claim 1, wherein the flow adjuster is selected from the group consisting of ketone peroxides, peroxyketals, hydroperoxides, dialkyl peroxides, diacyl peroxides, peroxydicarbonates, and peroxyesters.

4. A molded article comprising the polypropylene composition described in claim 1.