A POLYOLEFIN ALLOY WITH IMPROVED SURFACE HARDNESS AND SCRATCH RESISTANCE, AND PROCESSES FOR PRODUCING SAME

Abstract: A polyolefin alloy with improved surface hardness and scratch resistance. The alloy contains a blend of 40 to 80 % by weight of a polypropylene material consisting of a polypropylene homopolymer or a copolymer of propylene with ethylene and/or butadiene; 1 to 10 % by weight of a functionalized polypropylene material consisting of a grafted polypropylene homopolymer or copolymer of propylene with ethylene and/or butadiene; and optionally up to 40 % by weight of ethylene/propylene/polyene terpolymer (EPDM); and further contains 1 to 50 % by weight of a mineral which has been surface-treated with aminosilane and 1 to 15 % by weight of amorphous, fatty acid amide-treated silica gel. The improved surface hardness and scratch resistance of the polyolefin alloy seems to be due to chemical reaction of the functionalized polypropylene material with the surface-treated mineral, and with the fatty acid amide-treated silica gel, respectively.

Description: A polyolefin alloy with improved surface hardness and scratch resistance, and processes for producing same. s The present invention relates to a polyolefin alloy with im¬ proved surface hardness and scratch resistance, and processes for producing same. More specifically, the invention relates to a polyolefin alloy on the basis of a polypropylene mate¬ rial, a functionalized polypropylene material, a mineral, an 0 amorphous silica gel and optionally an ethylene/propylene/- polyene terpolymer (EPDM), as well as processes for producing said polyolefin alloy. Various techniques for increasing the scratch resistance of s polyolefin materials are previously known, i.a. addition of silica materials. Thus, JP 1318051 (Toray Silicone KK) dis¬ closes polyolefins which for this purpose have been modified with a filler on silica basis. Said filler may have been surface treated with silane type compounds. However, the disclosed polyolefins are not alloys and no fatty acid amide- treated silica gel is used in the material. JP 1104637 (Showa Denko KK) discloses materials on a polypropylene basis to which silica/alumina spheroids and a polypropylene material functionalized with carboxylic acid or carboxylic anhydride have been added. These materials also contains no fatty acid amide-treated silica gel. It has now been found that when a functionalized polypropylene material and an amorphous, fatty acid amide-modified silica gel are incorporated into certain polyolefin materials having a mineral content, the scratch resistance of the material is substantially improved, with retention of the impact strength and the thermal shape stability (HDTA) of the material. Thus, the invention provides a new polyolefin alloy having im¬ proved surface hardness and scratch resistance, and having a melt index MI in the range of 0.1 - 50 g/10 min at 230°C/2.16 kg, particularly in the range of 3 to 40 g/10 min at 230°C/- 2.16 kg. The polyolefin alloy is characterized in that it is constituted by a blend of: (A) 40 to 80% by weight of a polypropylene materia consisting of a polypropylene homopolymer or copolymer of propylene with ethylene and/o butadiene, which polypropylene material may hav a content of polymerized ethylene and/or buta diene units of 5 to 35 mole% and has a molecula weight Mw of 100,000 to 300,000 and a melt inde MI of 0.1 to 20 g/10 min at 230°C/2.16 kg, (B) 1 to 10% by weight of a functionalized polypro pylene material consisting of a grafted polypro pylene homopolymer or copolymer of propylen with ethylene and/or butadiene, having a degre of grafting of 0.2 to 10% by weight, (C) 1 to 50% by weight of a mineral, having a mea particle size of about 2.5 μm and a maximum par ticle size of about 20 μm, and being surface treated with 0.2 to 5% by weight of aminosilane (D) 1 to 15% by weight of amorphous fatty acid treated silica gel, comprising 25 to 75% b weight of silica and 75 to 25% by weight o fatty acid amide, (E) 0 to 40% by weight of an ethylene/propylene/ polyene terpolymer (EPDM) having a melt index M in the range of 1 to 10 g/10 min at 230°C/2.1 kg and a Shore D hardness of 30 to 70. EP-A-0 567 058 (Hirano et al. ) discloses compositions havin improved elasticity, peeling strength and recoating proper ties, comprising a polypropylene, an ethylene/α-olefin copoly mer elastomer, and a modified polyolefin having a functiona group in either or both ends thereof, as well as certain sub stituted amines/amides. In addition thereto, the composition can also contain various additives, among which talc is men tioned. Said compositions of EP-A-0 567 058 do not, however contain the combination of a functionalized polypropylen material of the same kind as component (B) of the polyolefi alloy of the present invention, with a mineral having bee surface-treated with an aminosilane, and a fatty acid-treate silica gel, and they do not suggest any improvement of the scratch resistance. US 4 675 122 (Lϋers et al. ) teaches a combined antiblocking agent and lubricant concentrate based on polyolefin, which contains diatomaceous earth, precipitated silica and/or silica gel as the antiblocking agent, and one more more amides of unsaturated C 18 -C 22 fatty acids. No mention is made of any improvement of the scratch-resistance. Also, it could not be considered to be near at hand to combine the teaching of US 4 675 122 with the teaching of the above-discussed EP-A-0 567 058, which also does not mention scratch-resistance. EP-A-0 297 693 (McKinney et al.) teaches a composition co pri- sing an intimate mixture of at least one ethylene interpolymer with acrylic acid, methacrylic acid or an ionomer of either of said acids and a slip-enhancing amount of a secondary fatty acid amide. The composition may also contain small amounts of finely divided inorganic materials such as silica and talc. The aim of the invention of EP-A-0 297 693 is to improve the slip and/or block characteristics of the ethylene interpoly- mers. No mention is made of any improvement of the scratch- resistance. Even though said EP-A-0 297 693 is disclosing compositions in which silica may be used, and will come into contact with fatty acid amide, it is not question there of any fatty acid-treated silica gel comprising 25-75% by weight of silica and 75-25% by weight of fatty acid amide as in the polyolefin alloy of the present invention. To the extent a finely inorganic material is used in the composition of EP-A-0 297 693, no surface treatment thereof with aminosilane is men¬ tioned, neither is there any mention of any functionalized polypropylene material. A similar composition is disclosed in EP-A-0 257 803 (Yamada et al.), comprising an ethylene/methyl methacrylate copolymer, a slip agent which may be a fatty acid amide, and a small amount (0.01-0.1 %wt) of an inorganic filler, which may be a silica or a talc. The composition is used to produce peelable protective films with low peeling strength for wrapping around e.g. rubbery articles having a tacky surface. Neither EP-A-0 257 803 nor EP-A-0 297 693 suggests the polyolefin alloy of the present invention havi improved surface hardness and scratch-resistance. US 5 286 791 (De Nicola et al.) discloses a filled compositi 5 having improved flexural modulus and impact strength, compr sing a propylene polymer material, a propylene polymer mat rial grafted with one or more vinyl monomers, and a rubb component. As filler, the composition may contain i.a. ta and silica, and column 3, lines 25-37, of the patent indicat o that the filler may be coated with an organic compound. Ho ever, the patent does not suggest any fatty acid amide-treat silica gel in combination with an aminosilane-treated miner and there is no suggestion in said patent that any such comb nation would improve the surface hardness and scratch-resis i5 ance of a polyolefin alloy as defined according to the prese invention. The new polyolefin alloy of the present invention can be pr duced by blending the components (A), (B), (C) and (D), a 20 optionally utilized component (E); melting and preferab kneading the blend; and then cooling and granulating t obtained blend. Alternatively, the new polyolefin alloy can be produced 25 blending the components (A) and (B) and optionally utiliz component (E); melting the blend; blending the components ( and (D) into the melt, preferably with kneading of the blen and then cooling and granulating the obtained blend. 30 The production of the polyolefin alloy can be effected in mixer of any suitable type, for instance a continuous batchwise mixer, although it is preferred to use an extruder. Particularly suitable polypropylene materials (A) for use 35 the new polyolefin alloy are copolymers of propylene and eth lene. A particularly suitable polypropylene material is a c polymer of propylene and ethylene having a content of 5 to 2 by weight of polymerized ethylene units. Suitable functionalized polypropylene materials (B) for use in the new polyolefin alloy are polypropylene homopolymers and copolymers of propylene and ethylene and/or butadiene (B), grafted with a compound selected from maleic anhydride, s acrylic acid, acrylates and methacrylates, vinyl silanes and other vinyl compounds. Particularly good results are obtained by grafting maleic anhydride on the polypropylene material. The functionalized polypropylene material can have a melt index MI in the range of 5 to 250 g/10 min at 230°C/2.16 kg, o more preferably in the range of 10 to 150 g/10 min at 230°C/2.16 kg. Suitable minerals (C) for use in the polyolefin alloy of the invention are finely divided minerals which have been silan- 5 ized with one or more of the aminosilanes traditionally used for surface treatment of talc. Particularly suitable minerals for use in the alloy after such silanizing treatment are wollastonite, kaolin, mica, calcium carbonate and talc, parti¬ cularly talc. Preferably, the treated mineral has a mean par- o ticle size D 50 in the range of 0.5 to 10 urn, more preferably 1-6 μm. The silica gel material (D) which is used in the polyolefin alloy of the invention is preferably a fatty amide-treated, 5 amorphous, synthetic silica gel containing 40 to 65% by weight of silica and 60 to 35% by weight of fatty acid amide. Ethylene/propylene/polyene terpolymers (EPDM) that are par¬ ticularly useful as an optional component in the polymer alloy o of the invention are such terpolymers which have an ethylene content of 30 to 90% by weight and a flow, determined accor¬ ding to the Mooney method (ML 101°C), of 0 to 60, more prefer¬ ably 0 to 50. 5 Although the invention is not meant to be limited by any par¬ ticular theory regarding the mechanism behind the improved surface hardness and scratch resistance achieved with the new polyolefin alloy, chemical reaction seems to take place between the functionalized polypropylene material (B) and the surface-treated mineral (C), and between the functionaliz polypropylene material (B) and the amorphous, fatty ac amide-treated silica gel (D). The following examples illustrate the preparation of the n polyolefin alloys of the invention. The following properti of the prepared alloys were measured: Modulus of elasticity: Measured at 23°C according ISO 527 (MPa). Notched Izod: Measured at -40°C according to ISO V 180/1A (kJ/m 2 ). Thermal shape stability (HDTA): Measured according ISO 75 ( °C). Shrinkage: Calculated directly (in %) from measur ments of length and width of a stamped square of sheet of thickness 2 mm, moulded under given injec tion moulding conditions. The test sheets for eac pair of Example illustrating the invention and Com parison Example were moulded under the same mouldin conditions. Scratch resistance: Measured with an Ericsson pe according to ISO 1518. Example 1 An alloy on polypropylene basis was prepared from the follow ing components: A. A copolymer of propylene and ethylene containin 14% by weight of polymerized ethylene and having a melt inde MI of 8.0 g/10 min at 230°C/2.16 kg. B. A polypropylene functionalized with maleic anhyd ride (MAH), containing 0.7% by weight of MAH and having a mel index MI of 200 g/10 min at 230°C/2.16 kg. C. A talc the surface of which has been treated wit 1.5 to 2.0% by weight of aminosilane, said talc having a den sity of 330 kg/m 3 and a particle size D 50 of 2 to 5 μm. D. An amorphous, synthetic, fatty acid amide-treate silica gel, containing 40 to 50% by weight of fatty acid amid (essentially 13-docoseneamide), having a density of 300 kg/ and a particle size D 50 of 2 to 4 μm. E. A low crystallinity ethylene/propylene/polyene terpolymer (EPDM) containing 47% of polymerized ethylene and having a density of 870 kg/m 3 and melt index MI of 0.6 g/10 min s at 230°C/2.16 kg. The alloy was prepared in a "Werner & Pfleiderer" double screw extruder, type ZSK, having 57 mm co-rotating screws. Before and after the preparation, the hopper was flushed with nitro¬ 0 gen gas in order that the preparation should take place in an approximately inert atmosphere. The screw speed was 200 rpm and the rate of extrusion was 80 kg/h. All the raw material was introduced gravimetrically at feed point 1. The tempera¬ ture profile of the extruder was maintained in the range of s 210 to 230 β C. The components added, the amounts thereof (in % by weight of the total blend) and the results are given in the table below. Fig. 1 shows the appearance of a test sample of the alloy after the scratch resistance having been measured with an Ericsson pen according to ISO 1518. 0 Example 2 (Comparison example) The procedure of Example 1 was followed, with the exception that the fatty acid amide-treated silica gel (component D) was omitted. The added components, the amounts thereof (in % by weight of the total blend) and the results are given in the table below. Fig. 2 shows the appearance of a test sample of the alloy after the scratch resistance having been measured with an Ericsson pen according to ISO 1518. Example 3 It was proceeded as in Example 1, with the exception that the amount of talc (component C) was increased from 10% by weight to 30% by weight. The added components, the amounts thereof (in % by weight of the total blend) and the results are given in the table below. Fig. 3 shows the appearance of a test sample of the alloy after the scratch resistance having been measured with an Ericsson pen according to ISO 1518. Example 4 (Comparison example) It was proceeded as in Example 2, with the exception that th amount of talc (component C) was increased from 10% by weigh to 30% by weight. The added components, the amounts thereo (in % by weight of the total blend) and the results are give in the table below. Fig. 4 shows the appearance of a tes sample of the alloy after the scratch resistance having bee measured with an Ericsson pen according to ISO 1518. Table Preparation of alloys on polypropylene basis, having improved scratch resistance. PP-g- Silica E-modu¬ Izod Shrink¬ Scratch Ex. ppl) MAH 2 Talc 3 ' gel*' EPDM lus -40°C HDTA age resist. (% wt) (% wt) (% wt) (% wt) (% wt) (MPa) (J/m) (°C) (%) (7,5 N) 1 70 5 10 5 10 1450 60 52 1,3 3 2 80 - 10 - 10 1600 50 54 1,3 0,5 (Comp. ) vD 3 50 5 30 5 10 2100 50 64 1,0 5 4 60 - 30 - 10 2400 35 68 0,7 1 (Comp. ) 1) A copolymer of propylene and ethylene with 14% by weight of polymerized ethylene and a MI 8.0 g/10 min at 230°C/2.16 kg. 2) A polypropylene functionalized with MAH, having a MAH content of 0.7% by weight and a MI of 200 g/10 min at 230°C/2.16 kg. 3) A talc surface-treated with 1.5 - 2.0% by weight of aminosilane, having a density of 330 kg/m 3 and a particle size D 50 pa 2-5 μm. 4) An amorphous, synthetic, fatty acie amide-treated silica, containing 40-50% by weight of fatty acid amide, and having a density of 300 kg/m 3 and a particle size D 50 of 2-4 μm. 5) A low crystallinity ethylene/propylene/polyene terpolymer (EPDM) containing 47% of polymerized ethylene, having a density of 870 kg/m 3 and a melt index MI of 0.6 g/10 min at 230°C/2.16 kg. 10 It can be seen from the results given in the above table, comparing Example 1 illustrating the invention and Comparis Example 2 illustrating the prior art, that addition of 5% weight of fatty acid amide-treated silica gel substantiall improves the scratch resistance of the alloy, which increas from 0.5 to 3. This improvement is also clearly seen by co paring Fig. 1, which shows the surface of a test sample of t alloy of Example 1 after the scratch resistance having be measured, with Fig. 2, which is a similar picture of a tes sample of the alloy of Example 2. The table further shows tha essential properties such as stiffness (E modulus) and shrink age are improved with the new technology, while the notch bar impact (Izod) at -40°C and the thermal shape stabilit (HDTA) are retained unaltered or are somewhat reduced. A similar comparison between the results obtained for th alloys of Example 3 and Example 4 (comparison example), i which examples 30% by weight of talc was used (vs. 10% b weight in Examples 1 and 2), shows that a substantial increas in the scratch resistance is achieved by adding 5% by weigh of fatty acid amide-treated silica gel, said scratch resist ance increasing from 1 to 5. The improvement is also clearl seen by comparing Fig. 3, which shows the surface of the ne alloy of Example 3 after the scratch resistance having bee measured, with Fig. 4, which is a similar picture of the allo of Example 4. It also appears from the table that the E modu lus and the shrinkage are improved for the alloy of Example 3 while the notched bar impact (Izod) at -40°C and the therma shape stability (HDTA) are retained unaltered or are somewha reduced.

Claims: Patent claims 1. A polyolefin alloy having improved surface hardness and scratch resistance, and having a melt index MI in the range of 0.1 to 50 g/10 min at 230°C/2.16 kg, particularly in the range of 3 to 40 g/10 min at 230°C/2.16 kg, characterized in that it is constituted by a blend of: (A) 40 to 80% by weight of a polypropylene material 0 consisting of a polypropylene homopolymer or a copolymer of propylene with ethylene and/or butadiene, which polypropylene material may have a content of polymerized ethylene and/or buta¬ diene units of 5 to 35 mole% and has a molecular s weight Mw of 100,000 to 300,000 and a melt index MI of 0.1 to 20 g/10 min at 230°C/2.16 kg, (B) 1 to 10% by weight of a functionalized polypro¬ pylene material consisting of a grafted polypro¬ pylene homopolymer or copolymer of propylene o with ethylene and/or butadiene, having a degree of grafting of 0.2 to 10% by weight, (C) 1 to 50% by weight of a mineral, having a mean particle size of about 2.5 μm and a maximum par¬ ticle size of about 20 μm, and being surface- 5 treated with 0.2 to 5% by weight of aminosilane, (D) 1 to 15% by weight of amorphous fatty acid- treated silica gel, comprising 25 to 75% by weight of silica and 75 to 25% by weight of fatty acid amide, 0 (E) 0 to 40% by weight of an ethylene/propylene/- polyene terpolymer (EPDM) having a melt index Ml in the range of 1 to 10 g/10 min at 230°C/2.16 kg and a Shore D hardness of 30 to 70. ' 2. A polyolefin alloy according to claim 1, charac¬ terized in that the functionalized polypropylene homopolymer or copolymer of propylene with ethylene and/or butadiene (B) is grafted with a compound selected from maleic anhydride, acrylic acid, acrylates and methacrylates, vinyl silanes and other vinyl compounds, preferably maleic anhydride. 3. A polyolefin alloy according to claim 1 or 2, charac terized in that the polypropylene material (A) is a copolyme s of propylene and ethylene and has a content of 5 to 25% b weight of polymerized ethylene units. 4. A polyolefin alloy according to any of claims 1 to 3 characterized in that it is constituted by a blend of: o 60 to 80 % by weight of (A); 2,5 to 7,5 % by weight of (B); 7,5 to 35 % by weight of (C); 2,5 to 7,5 % by weight of (D); 0 to 25 % by weight of (E). 5 5. A polyolefin alloy according to any of claims 1 to 4 characterized in that the functionalized polypropylene mate rial (B) has a degree of grafting of 0.5 to 2% by weight. 0 6. A polyolefin alloy according to any of claims 1 to 5 characterized in that the surface-treated mineral (C) has bee surface-treated with about 1% by weight of amino silane. 7. A polyolefin alloy according to any of claims 1 to 6 5 characterized in that the mineral (C) is selected from wollas tonite, kaolin, mica, calcium carbonate and talc. 8. A polyolefin alloy according to claim 7, characte rized in that the mineral (C) is talc. 0 9. A process for producing a polyolefin alloy accordin to any of claims 1 to 8, characterized by the steps of blen ding the components (A), (B), (C) and (D) and optionally uti lized component (E); melting and preferably kneading th 5 blend; and then cooling and granulating the obtained blend. 10. A process for producing a polyolefin alloy accordin to any of claims 1 to 8, characterized by the steps of blen ding the components (A) and (B) and optionally utilized com ponent (E); melting the blend; blending the components (C) and (D) into the melt, preferably with kneading of the blend; and then cooling and granulating the obtained blend.

Inventors: BAANN HENNING, BAANN, HENNING
Applicants: BAANN HENNING, BOREALIS AS, BAANN, HENNING, BOREALIS A/S
Application year: 1996
Main classification: C08L23
IPC codes: C08K13, C08L23