Patent Description:
One of the key challenges in the automotive industry is the desire to reduce the weight of a vehicle in order to decrease fuel consumption. Decreased fuel consumption would result in reduced pollution and would benefit the environment. Carbon fibers, with their low density (around <NUM>/cc) and high stiffness, offer an interesting source of substitution to conventional glass fibers (density of around <NUM>/cc) and high strength steel (density of around <NUM>/cc) currently used in the automotive industry. However, carbon fibers present impact performance challenges as they are very brittle and break down to small fibers after being compounded or injection molded into parts. Accordingly, a need exists for carbon fiber solutions that provide high stiffness and good impact performance while retaining a high and commercially interesting modulus.

A further challenge in the automotive industry is thermal expansion of polypropylene-based compounds. In the automotive industry, it is important to limit dimensional changes with temperature fluctuations. While glass fibers and talc are typical fillers used to limit the Coefficient of Linear Thermal Expansion (CLTE) in polypropylene-based compounds, a need exists for solutions for achieving even lower CLTE values <CIT> aims to provide automotive components made from engineered thermoplastic materials and blends which have a suitable CLTE.

In certain embodiments, the present disclosure relates to a composition comprising: (A) from <NUM> wt% to <NUM> wt% of a propylene component including at least one propylene-based polymer having a propylene content of at least <NUM> wt%, based on the total weight of the propylene-based polymer, and a melt flow rate of at least <NUM>/<NUM> minutes as measured by ISO <NUM> at <NUM>/<NUM>;(B) from <NUM> wt% to <NUM> wt% of a carbon fiber component; and(C) from <NUM> wt% to <NUM> wt% of a thermoplastic polyolefin elastomer, wherein the thermoplastic polyolefin elastomer is an olefin block copolymer, and wherein the composition further comprises a flexural modulus of greater than <NUM> MPa, as determined using a Zwick Z010 and performed according to ISO <NUM> standard, a Charpy impact strength of greater than <NUM> kJ/m2 , as determined using the method outlined in the description, and a falling dart maximum force energy of greater than <NUM> J, as determined using a Ceast Fractovis <NUM>/<NUM> and measured according to ISO <NUM>-<NUM> (<NUM> edition).

In further embodiments of the present disclosure, the composition described above may optionally include (D) from <NUM> wt% to <NUM> wt% of a compatibilization agent.

The numerical ranges disclosed herein include all values from, and including, the lower value and the upper value. For ranges containing explicit values, any subrange between any two explicit values is included. As used with respect to a chemical compound, unless specifically indicated otherwise, the singular includes all isomeric forms and vice versa.

All references to the Periodic Table of the Elements herein shall refer to the <NPL>. Also, any references to a Group or Groups shall be to the Groups or Groups reflected in this Periodic Table of the Elements using the IUPAC system for numbering groups. Unless stated to the contrary, implicit from the context, or customary in the art, all components and percents are based on weight.

"Composition" and like terms is a mixture of two or more components. Included in compositions are pre-reaction, reaction and post-reaction mixtures, the latter of which will include reaction products and by-products, as well as unreacted components of the reaction mixture and decomposition products, if any, formed from the one or more components of the pre-reaction or reaction mixture.

A "polymer" is a compound prepared by polymerizing monomers, whether of the same or a different type, that in polymerized form provide the multiple and/or repeating "units" or "mer units" that make up a polymer. The generic term polymer thus embraces the term homopolymer, usually employed to refer to polymers prepared from only one type of monomer, and the term copolymer, usually employed to refer to polymers prepared from at least two types of monomers. It also embraces all forms of copolymer, e.g., random, block, etc. "Interpolymer," as used herein, refers to a polymer having polymerized therein at least two monomers and includes, for example, copolymers, terpolymers and tetrapolymers.

The terms "ethylene/α-olefin polymer" and "propylene/α-olefin polymer" are indicative of copolymer as described above prepared from polymerizing ethylene or propylene, respectively, and one or more additional, polymerizable α-olefin monomer. It is noted that although a polymer is often referred to as being "made of" one or more specified monomers, "based on" a specified monomer or monomer type, "containing" a specified monomer content, or the like, in this context the term "monomer" is understood to be referring to the polymerized remnant of the specified monomer and not to the unpolymerized species. In general, polymers herein are referred to as being based on "units" that are the polymerized form of a corresponding monomer.

As used herein, "alpha-olefin" or "α-olefin" refer to olefins or alkenes with the chemical formula CxH2x, distinguished by having a double bond at the primary or alpha (α) position. As used herein, alpha-olefins include, but are not limited to, ethylene, propylene, <NUM>-butene, <NUM>-pentene, <NUM>-hexene, <NUM>-methyl-<NUM>-pentene, <NUM>-heptene, <NUM>-octene, <NUM>-nonene, <NUM>-decene, <NUM>-dodecene, and the like.

The terms "ethylene/α-olefin interpolymer" and "ethylene/α-olefin multi-block interpolymer," as used herein, refer to an interpolymer that comprises a polymerized ethylene monomer and at least one α-olefin.

"Blend," "polymer blend," and like terms is a composition of two or more polymers. Such a blend may or may not be miscible. Such a blend may or may not be phase separated. Such a blend may or may not contain one or more domain configurations, as determined from transmission electron spectroscopy, light scattering, x-ray scattering, and any other method known in the art.

"Units derived from ethylene," "ethylene content," and like terms mean the units of a polymer formed from the polymerization of ethylene monomers. "Units derived from α-olefin," "alpha-olefin content," "α-olefin content," and like terms mean the units of a polymer formed from the polymerization of specific α-olefin monomers. "Units derived from propylene," "propylene content," and like terms mean the units of a polymer formed from the polymerization of propylene monomers.

"Propylene based polymer" and like terms mean a polymer that comprises a majority weight percent of polymerized propylene monomer, also referred to as units derived from propylene (based on the total amount of polymerizable monomers), and optionally comprises at least one polymerized comonomer different from propylene (such as at least one selected from a C<NUM> and C<NUM>-<NUM> α-olefin) so as to form a propylene-based interpolymer. For example, when the propylene-based polymer is a copolymer, the propylene content is greater than <NUM> wt%, based on the total weight of the copolymer.

"Ethylene based polymer" and like terms mean a polymer that comprises a majority weight percent polymerized ethylene monomer, also referred to as units derived from ethylene (based on the total weight of polymerizable monomers), and optionally may comprise at least one polymerized comonomer different from ethylene (such as at least one selected from a C3-<NUM>α-olefin) so as to form an ethylene-based interpolymer. For example, when the ethylene-based polymer is a copolymer, the amount of ethylene is greater than <NUM> wt%, based on the total weight of the copolymer.

The term "polyethylene" includes homopolymers of ethylene and copolymers of ethylene and one or more C3-<NUM>α-olefins in which ethylene comprises at least <NUM> mole percent. The term "polypropylene" includes homopolymers of propylene, such as isotactic polypropylene, atactic polypropylene, syndiotactic polypropylene, and copolymers of propylene and one or more C2 and C4-<NUM>α-olefins in which propylene comprises at least <NUM> mole percent.

The term "crystalline" refers to a polymer or polymer block that possesses a first order transition or crystalline melting point (Tm) as determined by differential scanning calorimetry (DSC) or equivalent technique. The term may be used interchangeably with the term "semicrystalline".

The term "crystallizable" refers to a monomer that can polymerize such that the resulting polymer is crystalline. Crystalline ethylene polymers typically have, but are not limited to, densities of <NUM>/cc to <NUM>/cc and melting points of <NUM> to <NUM>. Crystalline propylene polymers may have, but are not limited to, densities of <NUM>/cc to <NUM>/cc and melting points of <NUM> to <NUM>.

The term "amorphous" refers to a polymer lacking a crystalline melting point as determined by differential scanning calorimetry (DSC) or equivalent technique.

The term "isotactic" is defined as polymer repeat units having at least <NUM> percent isotactic pentads as determined by <NUM>C-NMR analysis. "Highly isotactic" is defined as polymers having at least <NUM> percent isotactic pentads.

The composition includes from <NUM> wt% to <NUM> wt% (e.g., from <NUM> wt% to <NUM> wt%, from <NUM> wt% to <NUM> wt%, from <NUM> wt% to <NUM> wt%, from <NUM> wt% to <NUM> wt%, from <NUM> wt% to <NUM> wt%, and/or from <NUM> wt% to <NUM> wt%) of a propylene component. The propylene component includes at least one propylene based polymer having a propylene content of at least <NUM> wt% (e.g., at least <NUM> wt%, at least <NUM> wt%, at least <NUM> wt%, at least <NUM> wt%, at least <NUM> wt%, and/or at least <NUM> wt%), based on the total weight of the propylene based polymer. The propylene based polymer may consist of heterogeneous polypropylene or homogeneous polypropylene.

The melt flow rate of the propylene based polymer may be from <NUM> g/<NUM> min to <NUM> g/<NUM> min according to ASTM D-<NUM> or ISO <NUM> at <NUM>, <NUM> (e.g., from <NUM>/<NUM> to <NUM>/<NUM>, from <NUM>/<NUM> to <NUM>/<NUM>, from <NUM>/<NUM> to <NUM>/<NUM>, etc.). In certain embodiments, the melt flow rate of the propylene based polymer may be at least <NUM>/<NUM> according to ASTM D-<NUM> or ISO <NUM> at <NUM>, <NUM>. The density of the propylene based polymer may be, in accordance with ASTM D792 or ISO <NUM>, from <NUM>/cc to <NUM>/cc (e.g., from <NUM>/cc to <NUM>/cc, from <NUM>/cc to <NUM>/cc, and/or from <NUM>/cc to <NUM>/cc). The flexural modulus of the propylene based polymer may be, in accordance with ASTM D790 or ISO <NUM>, from <NUM> MPa to <NUM> MPa (e.g., from <NUM> MPa to <NUM> MPa, from <NUM> MPa to <NUM> MPa and/or from <NUM> MPa to <NUM> MPa).

The propylene based polymer may be a propylene homopolymer, a propylene based copolymer or interpolymer, a random copolymer polypropylene (RCPP), a high density polypropylene (HDPP), a heterophasic polypropylene, an impact copolymer polypropylene (e.g., homopolymer propylene modified with at least one elastomeric impact modifier) (ICPP), a high impact polypropylene (HIPP), a high melt strength polypropylene (HMS-PP), an isotactic polypropylene (iPP), a syndiotactic polypropylene (sPP), or a combination thereof. In exemplary embodiments, the propylene based polymer may be in the isotactic form of homopolymer polypropylene, although other forms of polypropylene may be used (e.g., syndiotactic or atactic). In exemplary embodiments, the propylene based polymer may be a polypropylene homopolymer or a polypropylene copolymer comprising not more than <NUM> wt% (e.g., not more than <NUM> wt%, not more than <NUM> wt%, not more than <NUM> wt%, and/or not more than <NUM> wt%) of a C2-C10 alpha-olefin other than propylene. In exemplary embodiments, the propylene based polymer serves as a polymer matrix (e.g., polypropylene matrix) to which further components may be added or dispersed.

Exemplary propylene-based polymers are formed by means within the skill in the art, for example, using single site catalysts (metallocene or constrained geometry) or Ziegler natta catalysts. Exemplary comonomers for polymerizing with propylene include ethylene, <NUM>-butene, <NUM> pentene, <NUM>-hexene, <NUM>-heptene, <NUM>-octene, <NUM>-nonene, <NUM>-decene, <NUM>-unidecene, <NUM> dodecene, as well as <NUM>-methyl-<NUM>-pentene, <NUM>-methyl-<NUM>-hexene, <NUM>-methyl-<NUM>-hexene, vinylcyclohexane, and styrene. Exemplary comonomers include ethylene, <NUM>-butene, <NUM>-hexene, and <NUM>-octene. Exemplary propylene based interpolymers include propylene/ethylene, propylene/<NUM>-butene, propylene/<NUM>-hexene, propylene/<NUM>-methyl-<NUM>-pentene, propylene/<NUM>-octene, propylene/ethylene/<NUM>-butene, propylene/ethylene/ENB, propylene/ethylene/<NUM>-hexene, propylene/ethylene/<NUM>-octene, propylene/styrene, and propylene/ethylene/styrene. Optionally, the propylene-based polymer includes a monomer having at least two double bonds such as dienes or trienes. Other unsaturated comonomers include, e.g., <NUM>,<NUM>-pentadiene, norbornadiene, and dicyclopentadiene; C8-<NUM> vinyl aromatic compounds including styrene, o-, m-, and p-methylstyrene, divinylbenzene, vinylbiphenyl, vinylnapthalene; and halogen-substituted C8-<NUM> vinyl aromatic compounds such as chlorostyrene and fluorostyrene.

In exemplary embodiments, the propylene-based polymer may be a propylene-alpha-olefin copolymer, which is characterized as having substantially isotactic propylene sequences. "Substantially isotactic propylene sequences" means that the sequences have an isotactic triad (mm) measured by <NUM>C NMR of greater than <NUM>; in the alternative, greater than <NUM>; in another alternative, greater than <NUM>; and in another alternative, greater than <NUM>. Isotactic triads are well-known in the art and are described in, for example, <CIT> and International Publication No. <CIT>, which refers to the isotactic sequence in terms of a triad unit in the copolymer molecular chain determined by <NUM>C NMR spectra.

In certain embodiments, the propylene/α-olefin copolymers are further characterized as containing an average of at least <NUM>, preferably an average of at least <NUM> and more preferably an average of at least <NUM>, long chain branches/<NUM> total carbons. The maximum number of long chain branches in the propylene/alpha-olefin copolymer is not critical, but typically it does not exceed <NUM> long chain branches/<NUM> total carbons. The term "long chain branch," as used herein, refers to a chain length greater than that resulting from the incorporation of the comonomer into the polymer backbone. Furthermore, the term "long chain branch" refers to a chain length of at least one carbon more than a short chain branch, and "short chain branch," as used herein, refers to a chain length of two carbons less than the number of carbons in the comonomer. For example, a propylene/<NUM>-octene interpolymer has backbones with long chain branches of at least seven (<NUM>) carbons in length, but these backbones also have short chain branches of only six (<NUM>) carbons in length.

Further parameters of the propylene based polymers (e.g., molecular weight, molecular weight distribution, melting temperature, impact strength, tensile properties, etc.) will be known by those of ordinary skill in the art based on the present disclosures and can be determined by methods known in the polymer art.

The composition includes from <NUM> wt% to <NUM> wt% (e.g., from <NUM> wt% to <NUM> wt%, from <NUM> wt% to <NUM> wt%, and/or from <NUM> wt% to <NUM> wt%) of a carbon fiber component. In exemplary embodiments, the carbon fiber component comprises chopped carbon fibers derived from recycled waste. The chopped carbon fibers may be produced by any process or means known to one of ordinary skill in the art. In a non-limiting, exemplary embodiment, the chopped carbon fibers are manufactured from a polyacrylonitrile (PAN) precursor via oxidation at around <NUM>-<NUM>, carbonization at around <NUM>-<NUM>, surface treatment, sizing, winding as a continuous carbon fiber tow, and cutting into chopped carbon fibers. In further exemplary embodiments, the chopped carbon fibers are produced by creating a weave from continuous carbon fiber and using the weave in a molding process followed by cutting the edge trim and using that as a source of chopped fiber.

In certain embodiments, the chopped carbon fibers have a fiber length of <NUM> to <NUM> prior to any processing (e.g., molding). In exemplary embodiments, the chopped carbon fibers have a fiber length of <NUM> prior to any processing (e.g., molding). In certain embodiments, the carbon fiber component is comprised of short carbon fibers and long carbon fibers. In certain embodiments, the chopped carbon fibers have a filament diameter of between <NUM> microns and <NUM> microns. In certain embodiments, the chopped carbon fibers have a density from <NUM>/cc to <NUM>/cc (e.g., from <NUM>/cc to <NUM>/cc) in accordance with ISO <NUM>. In certain embodiments, the chopped carbon fibers have a tensile strength from <NUM> MPa to <NUM> MPa (e.g., from <NUM> MPa to <NUM> MPa, from <NUM> MPa to <NUM> MPa and/or from <NUM> MPa to <NUM> MPa) in accordance with ISO <NUM>. In certain embodiments, the chopped carbon fibers have a tensile modulus from <NUM> GPa to <NUM> GPa (e.g., <NUM> GPa to <NUM> GPa, from <NUM> GPa to <NUM> GPa and/or from <NUM> GPa to <NUM> GPa) in accordance with ISO <NUM>. In certain embodiments, the chopped carbon fibers have an elongation at break from <NUM>% to <NUM>% (e.g., from <NUM>% to <NUM>%, from <NUM>% to <NUM>% and/or from <NUM>% to <NUM>%) in accordance with ISO <NUM>. In certain embodiments, the chopped carbon fibers have a bulk density from <NUM>/<NUM> to <NUM>/l in accordance with ISO <NUM>.

The chopped carbon fibers may be coated with various sizings. Exemplary sizings for the chopped carbon fibers of the present disclosure include polyurethanebased emulsions, epoxy-based emulsions, phenoxy-based emulsions, epoxy- and phenoxy-based emulsions, aromatic polymer based emulsions, glycerin-based emulsions, hydrocarbon-based emulsions, polyamide-based emulsions, and/or combinations thereof. In certain embodiments, the chopped carbon fibers have a sizing content from <NUM> wt% to <NUM> wt% (e.g., from <NUM> wt% to <NUM> wt%).

In certain embodiments, the carbon fiber component comprises chopped carbon fibers commercially available from, for example, SGL Group (e.g., SIGRAFIL® carbon fibers), DowAksa, Toray (e.g., TORAYCA™ carbon fibers), etc..

The composition may include from <NUM> wt% to <NUM> wt% (e.g., from <NUM> wt% to <NUM> wt%, from <NUM> wt% to <NUM> wt%, and/or from <NUM> wt% to <NUM> wt%) of at least one thermoplastic polyolefin elastomer. In certain embodiments, the TPE component provides toughness to the composition. In certain embodiments, the TPE component is a polyolefin (PO) that (<NUM>) has the properties of an elastomer, i.e., the ability to be stretched beyond its original length and retract to substantially its original length when released, and (<NUM>) can be processed like a thermoplastic, i.e., to soften when exposed to heat and return to substantially its original condition when cooled to room temperature.

In certain embodiments, the compositions of the present disclosure comprise a matrix polymer toughened with at least one thermoplastic polyolefin elastomer, the matrix polymer being the propylene component described above. Suitable TPEs may be any elastomer with sufficient polypropylene compatibility and sufficiently low enough glass transition temperature to impart impact toughness to the propylene component. Nonlimiting examples of suitable TPE's include styrenic block copolymers (e.g., SEBS block copolymers), ethylene/α-olefin multi-block interpolymers (OBCs) (e.g., INFUSE™) and propylene-based olefin block copolymers (e.g., INTUNE™),.

In exemplary embodiments of the composition of the present disclosure, the TPE component includes multi-block interpolymers. In exemplary embodiments of the composition of the present disclosure, the TPE component includes ethylene/α-olefin multi-block interpolymers.

In certain embodiments, selectively hydrogenated block copolymers can be used as the toughening elastomer including block copolymers of conjugated dienes and vinyl aromatic hydrocarbons which exhibit elastomeric properties and which have <NUM>,<NUM>-microstructure contents prior to hydrogenation of from about <NUM>% to about <NUM>%. Such block copolymers may be multiblock copolymers of varying structures containing various ratios of conjugated dienes to vinyl aromatic hydrocarbons including those containing up to about <NUM> percent by weight of vinyl aromatic hydrocarbon. Thus, multiblock copolymers may be utilized which are linear or radial, symmetric, or asymmetric and which have structures represented by the formulae, A-B, A-B-A, A-B-A-B, B-A, B-A-B, B-A-B-A, (AB)<NUM>,<NUM>,<NUM>. BA and the like wherein A is a polymer block of a vinyl aromatic hydrocarbon or a conjugated diene/vinyl aromatic hydrocarbon tapered copolymer block and B is a polymer block of a conjugated diene.

In certain embodiments, the TPE component includes a styrenic block copolymer, such as a polystyrene-block-poly(ethylene-co-butylene)-block-polystyrene (SEBS) triblock thermoplastic elastomer. In general, styrenic block copolymers suitable for the invention include at least two mono-alkenyl arene blocks, preferably two polystyrene blocks, separated by a block of saturated conjugated diene, preferably a saturated polybutadiene block. The preferred styrenic block copolymers have a linear structure, although in some embodiments, branched or radial polymers or functionalized block copolymers make useful compounds. The total number average molecular weight of the styrenic block copolymer is preferably from <NUM>,<NUM> to <NUM>,<NUM> if the copolymer has a linear structure. Such block copolymers typically have an average polystyrene content from <NUM> to <NUM>, more typically from <NUM> to <NUM> wt % of the copolymer.

The block styrenic copolymers may be produced by any well known ionic block polymerization or copolymerization procedures including the well known sequential addition of monomer techniques, incremental addition of monomer techniques or coupling techniques as illustrated in, for example, <CIT>, <CIT>,<CIT>, and <CIT>. As is well known in the block copolymer art, tapered copolymer blocks can be incorporated in the multiblock copolymer by copolymerizing a mixture of conjugated diene and vinyl aromatic hydrocarbon monomers utilizing the difference in their copolymerization reactivity rates. Various patents describe the preparation of multiblock copolymers containing tapered copolymer blocks including <CIT>, <CIT>,<CIT>, and <CIT>.

In certain embodiments, the at least one thermoplastic polyolefin elastomer is an olefin block copolymer. The term "olefin block copolymer" or "OBC" means (and is interchangeable with) an "ethylene/α-olefin multi-block interpolymer" and includes ethylene and one or more copolymerizable α-olefin comonomer in polymerized form, characterized by multiple blocks or segments of two or more polymerized monomer units differing in chemical or physical properties. The term "ethylene/α-olefin multi-block copolymer" includes block copolymer with two blocks (di-block) and more than two blocks (multi-block). The terms "interpolymer" and "copolymer" are used interchangeably herein. When referring to amounts of "ethylene" or "comonomer" in the interpolymer, it is understood that this means polymerized units thereof. In some embodiments, the ethylene/α-olefin interpolymer is an ethylene/α-olefin multi-block interpolymer. In some embodiments, the ethylene/α-olefin multi-block copolymer can be represented by the following formula:.

where n is at least <NUM>, preferably an integer greater than <NUM>, such as <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, or higher, "A" represents a hard block or segment and "B" represents a soft block or segment. Preferably, As and Bs are linked, or covalently bonded, in a substantially linear fashion, or in a linear manner, as opposed to a substantially branched or substantially star-shaped fashion. In other embodiments, A blocks and B blocks are randomly distributed along the polymer chain. In other words, the block copolymers usually do not have a structure as follows. AAA-AA-BBB-BB.

In certain embodiments, the block copolymers do not usually have a third type of block, which comprises different comonomer(s). In yet other embodiments, each of block A and block B has monomers or comonomers substantially randomly distributed within the block. In other words, neither block A nor block B comprises two or more sub-segments (or sub-blocks) of distinct composition, such as a tip segment, which has a substantially different composition than the rest of the block.

Preferably, ethylene comprises the majority mole fraction of the whole block copolymer, i.e., ethylene comprises at least <NUM> mole percent of the whole polymer. More preferably ethylene comprises at least <NUM> mole percent, at least <NUM> mole percent, or at least <NUM> mole percent, with the substantial remainder of the whole polymer comprising at least one other comonomer that is preferably an α-olefin having <NUM> or more carbon atoms, or <NUM> or more carbon atoms. In some embodiments, the ethylene/α-olefin multi-block copolymer may comprise <NUM> mol% to <NUM> mol% ethylene, or <NUM> mol% to <NUM> mol% ethylene, or <NUM> mol% to <NUM> mol% ethylene. For many ethylene/octene multi-block copolymers, the composition comprises an ethylene content greater than <NUM> mole percent of the whole polymer and an octene content of from <NUM> to <NUM>, or from <NUM> to <NUM> mole percent of the whole polymer.

The ethylene/α-olefin multi-block copolymer includes various amounts of "hard" segments and "soft" segments. "Hard" segments are blocks of polymerized units in which ethylene is present in an amount greater than <NUM> weight percent, or <NUM> weight percent, or greater than <NUM> weight percent, or greater than <NUM> weight percent based on the weight of the polymer, up to <NUM> weight percent. In other words, the comonomer content (content of monomers other than ethylene) in the hard segments is less than <NUM> weight percent, or <NUM> weight percent, or less than <NUM> weight percent, or less than <NUM> weight percent based on the weight of the polymer, and can be as low as zero. In some embodiments, the hard segments include all, or substantially all, units derived from ethylene. "Soft" segments are blocks of polymerized units in which the comonomer content (content of monomers other than ethylene) is greater than <NUM> weight percent, or greater than <NUM> weight percent, greater than <NUM> weight percent, or greater than <NUM> weight percent based on the weight of the polymer. In some embodiments, the comonomer content in the soft segments can be greater than <NUM> weight percent, greater than <NUM> weight percent, greater than <NUM> weight percent, greater than <NUM> weight percent, greater than <NUM> weight percent, greater than <NUM> weight percent, greater than <NUM> weight percent, or greater than <NUM> weight percent and can be up to <NUM> weight percent.

The soft segments can be present in an ethylene/α-olefin multi-block copolymer from <NUM> weight percent to <NUM> weight percent of the total weight of the ethylene/α-olefin multi-block copolymer, or from <NUM> weight percent to <NUM> weight percent, from <NUM> weight percent to <NUM> weight percent, from <NUM> weight percent to <NUM> weight percent, from <NUM> weight percent to <NUM> weight percent, from <NUM> weight percent to <NUM> weight percent, from <NUM> weight percent to <NUM> weight percent, from <NUM> weight percent to <NUM> weight percent, from <NUM> weight percent to <NUM> weight percent, or from <NUM> weight percent to <NUM> weight percent of the total weight of the ethylene/α-olefin multi-block copolymer. Conversely, the hard segments can be present in similar ranges. The soft segment weight percentage and the hard segment weight percentage can be calculated based on data obtained from DSC or NMR. Such methods and calculations are disclosed in, for example, <CIT>. and assigned to Dow Global Technologies Inc. In particular, hard segment and soft segment weight percentages and comonomer content may be determined as described in Column <NUM> to Column <NUM> of <CIT>.

The ethylene/α-olefin multi-block copolymer is a polymer comprising two or more chemically distinct regions or segments (referred to as "blocks") preferably joined (or covalently bonded) in a linear manner, that is, a polymer comprising chemically differentiated units which are joined end-to-end with respect to polymerized ethylenic functionality, rather than in pendent or grafted fashion. In an embodiment, the blocks differ in the amount or type of incorporated comonomer, density, amount of crystallinity, crystallite size attributable to a polymer of such composition, type or degree of tacticity (isotactic or syndiotactic), regio-regularity or regio-irregularity, amount of branching (including long chain branching or hyper-branching), homogeneity or any other chemical or physical property. Compared to block interpolymers of the prior art, including interpolymers produced by sequential monomer addition, fluxional catalysts, or anionic polymerization techniques, the present ethylene/α-olefin multi-block copolymer is characterized by unique distributions of both polymer polydispersity (PDI or Mw/Mn or MWD), polydisperse block length distribution, and/or polydisperse block number distribution, due, in an embodiment, to the effect of the shuttling agent(s) in combination with multiple catalysts used in their preparation.

In an embodiment, the ethylene/α-olefin multi-block copolymer is produced in a continuous process and possesses a polydispersity index (Mw/Mn) from <NUM> to <NUM>, or from <NUM> to <NUM>, or from <NUM> to <NUM>, or from <NUM> to <NUM>. When produced in a batch or semi-batch process, the ethylene/α-olefin multi-block copolymer possesses Mw/Mn from <NUM> to <NUM>, or from <NUM> to <NUM>, or from <NUM> to <NUM>, or from <NUM> to <NUM>.

In addition, the ethylene/α-olefin multi-block copolymer possesses a PDI (or Mw/Mn) fitting a Schultz-Flory distribution rather than a Poisson distribution. The present ethylene/α-olefin multi-block copolymer has both a polydisperse block distribution as well as a polydisperse distribution of block sizes. This results in the formation of polymer products having improved and distinguishable physical properties. The theoretical benefits of a polydisperse block distribution have been previously modeled and discussed in <NPL>, and <NPL>.

In an embodiment, the present ethylene/α-olefin multi-block copolymer possesses a most probable distribution of block lengths.

In a further embodiment, the ethylene/α-olefin multi-block copolymer of the present disclosure, especially those made in a continuous, solution polymerization reactor, possess a most probable distribution of block lengths. In an embodiment, the ethylene multi-block copolymer is defined as having:.

The ethylene/α-olefin multi-block copolymer may also have:.

It is understood that the ethylene/α-olefin multi-block interpolymer may have one, some, all, or any combination of properties (A)-(G). Block Index can be determined as described in detail in <CIT>. Analytical methods for determining properties (A) through (G) are disclosed in, for example, <CIT>, Col. <NUM>, line <NUM> through Col. <NUM>, line <NUM>.

The ethylene/α-olefin multi-block interpolymer, and further copolymer, may comprise any one of properties (A) through (G), or may comprises a combination of two or more of (A) through (G).

Another type of ethylene/α-olefin multi-block interpolymers that may be used are those referred to as "mesophase separated". The term "mesophase separation" means a process in which polymeric blocks are locally segregated to form ordered domains. Crystallization of the ethylene segments in these systems is primarily constrained to the resulting mesodomains and such systems may be referred to as "mesophase separated". These mesodomains can take the form of spheres, cylinders, lamellae, or other morphologies known for block copolymers. The narrowest dimension of a domain, such as perpendicular to the plane of lamellae, is generally greater than about <NUM> in the mesophase separated block copolymers of the instant invention. In some embodiments, the olefin block copolymer is mesophase separated. Examples of these interpolymers may be found in, for example, International Publication Nos. <CIT>, <CIT>, <CIT>, <CIT>, <CIT>, and <CIT>.

With respect to the mesophase separated olefin block copolymers, in some embodiments, the delta comonomer is greater than <NUM> mol %, greater than <NUM> mol % or greater than <NUM> mol %. The delta comonomer can be from <NUM> mol % to <NUM> mol %, from <NUM> mol % to <NUM> mol % or from <NUM> mol % to <NUM> mol %. The term 'delta comonomer' means the difference in mole percent comonomer between the hard segment and the soft segment of the olefin block copolymer. The delta comonomer can be measured using<NUM>C NMR such as described below and in <CIT>. In certain embodiments, the ethylene/α-olefin multi-block interpolymer has a soft segment composd of from <NUM> mol% to <NUM> mol% derived from the comonomer (e.g., octene).

Suitable monomers for use in preparing the present OBC include ethylene and one or more addition polymerizable monomers other than ethylene. Examples of suitable comonomers include straight-chain or branched α-olefins of <NUM> to <NUM>, preferably <NUM> to <NUM>, carbon atoms, such as propylene, <NUM>-butene, <NUM>-pentene, <NUM>-methyl-<NUM>-butene, <NUM>-hexene, <NUM>-methyl-<NUM>-pentene, <NUM>-methyl-<NUM>-pentene, <NUM>-octene, <NUM>-decene, <NUM>-dodecene, <NUM>-tetradecene, <NUM>-hexadecene, <NUM>-octadecene and <NUM>-eicosene; cyclo-olefins of <NUM> to <NUM>, preferably <NUM> to <NUM>, carbon atoms, such as cyclopentene, cycloheptene, norbornene, <NUM>-methyl-<NUM>-norbornene, tetracyclododecene, and <NUM>-methyl-<NUM>,<NUM>,<NUM>,<NUM>-dimethano-<NUM>,<NUM>,<NUM>,<NUM>,4a,<NUM>,<NUM>,8a-octahydro-naphthalene; di- and polyolefins, such as butadiene, isoprene, <NUM>-methyl-<NUM>,<NUM>-pentadiene, <NUM>,<NUM>-pentadiene, <NUM>,<NUM>-pentadiene, <NUM>,<NUM>-hexadiene, <NUM>,<NUM>-hexadiene, <NUM>,<NUM>-hexadiene, <NUM>,<NUM>-octadiene, <NUM>,<NUM>-octadiene, <NUM>,<NUM>-octadiene, <NUM>,<NUM>-octadiene, <NUM>,<NUM>-octadiene, ethylidenenorbornene, vinyl norbornene, dicyclopentadiene, <NUM>-methyl-<NUM>,<NUM>-octadiene, <NUM>-ethylidene-<NUM>-methyl-<NUM>,<NUM>-nonadiene, and <NUM>,<NUM>-dimethyl-<NUM>,<NUM>,<NUM>-decatriene; and <NUM>-phenylpropene, <NUM>-phenylpropene, <NUM>,<NUM>-difluoroethylene, tetrafluoroethylene, and <NUM>,<NUM>,<NUM>-trifluoro-<NUM>-propene. Preferred α-olefins include, but are not limited to, C3-C20 α-olefins, and preferably C3-C10 α-olefins. More preferred α-olefins include propylene, <NUM>-butene, <NUM>-pentene, <NUM>-hexene, <NUM>-heptene and <NUM>-octene, and more preferably include propylene, <NUM>-butene, <NUM>-hexene and <NUM>-octene.

The olefin block copolymers can be produced via a chain shuttling process such as described in <CIT>. In particular, suitable chain shuttling agents and related information are listed in Col. <NUM>, line <NUM> through Col. <NUM>, line <NUM>. Suitable catalysts are described in Col. <NUM>, line <NUM> through Col. <NUM>, line <NUM> and suitable co-catalysts in Col. <NUM>, line <NUM> through Col. <NUM> line <NUM>. The process is described throughout the document, but particularly in Col. Col <NUM>, line <NUM> through Col. <NUM>, line <NUM>. The process is also described, for example, in the following: <CIT>; <CIT>; and <CIT>. Further exemplary catalytic processes include those disclosed in <CIT>, which is herein incorporated by reference.

In certain embodiments, the ethylene/α-olefin multi-block interpolymer has a density greater than <NUM>/cc, further greater than <NUM>/cc, and further greater than <NUM>/cc. The density may be, for example, from <NUM>/cc to <NUM>/cc, from <NUM>/cc to <NUM>/cc, and from <NUM> to <NUM>/cc. Density is measured by the procedure of ASTM D-<NUM> or ISO <NUM>.

In certain embodiments, the ethylene/α-olefin multi-block interpolymer, and further copolymer, has a melting point of greater than <NUM>° C. , further greater than <NUM>° C. The melting point is measured by Differential Scanning calorimetry (DSC) method described in <CIT> (<CIT>).

In certain embodiments, the ethylene/α-olefin multi-block interpolymer, and further copolymer, has a melt index (I2) greater than, or equal to, <NUM>/<NUM>, and further greater than, or equal to, <NUM> g/<NUM> min, as determined using ASTM D-<NUM> or ISO <NUM> (<NUM>° C. , <NUM> load).

In certain embodiments, the ethylene/α-olefin multi-block interpolymer, and further copolymer, has a melt index (I2) less than, or equal to, <NUM> g/<NUM> min, further less than, or equal to, <NUM>/<NUM>, and further less than, or equal to, <NUM>/<NUM>, as determined using ASTM D-<NUM> or ISO <NUM> (<NUM>° C. , <NUM> load).

The composition may include from <NUM> wt% to <NUM> wt% (e.g., from <NUM> wt% to <NUM> wt%, from <NUM> wt% to <NUM> wt%, and/or from <NUM> wt% to <NUM> wt%) of a compatibilization agent. In certain embodiments of the present disclosure, the chopped carbon fibers described above are chemically bonded into the polypropylene matrix through use of a compatibilization agent to enable excellent mechanical properties. In certain embodiments, the composition of the present disclosure may be modified by, for example, grafting, hydrogenation, nitrene insertion reactions, or other functionalization reactions using compatibilization agents such as those known to those skilled in the art.

A variety of radically graftable species as compatibilization agents may be used, either individually, or as relatively short grafts. These species include unsaturated molecules, each containing at least one heteroatom. These species include, but are not limited to, maleic anhydride, dibutyl maleate, dicyclohexyl maleate, diisobutyl maleate, dioctadecyl maleate, N-phenylmaleimide, citraconic anhydride, tetrahydrophthalic anhydride, bromomaleic anhydride, chloromaleic anhydride, nadic anhydride, methylnadic anhydride, alkenylsuccinic anhydride, maleic acid, fumaric acid, diethyl fumarate, itaconic acid, citraconic acid, crotonic acid, and the respective esters, imides, salts, and Diels-Alder adducts of these compounds. These species also include silane compounds.

Radically graftable species of the silane class of materials may be attached to the polymer, either individually, or as relatively short grafts. These species include, but are not limited to, vinylalkoxysilanes, vinyltrimethoxysilane, vinyltriethoxysilane, vinyltriacetoxysilane, vinyltrichlorosilane, and the like. Generally, materials of this class include, but are not limited to, hydrolyzable groups, such as alkoxy, acyloxy, or halide groups, attached to silicon. Materials of this class also include non-hydrolyzable groups, such as alkyl and siloxy groups, attached to silicon.

Other radically graftable species may be attached to the polymer, individually, or as short-to-longer grafts. These species include, but are not limited to, methacrylic acid; acrylic acid; Diels-Alder adducts of acrylic acid; methacrylates including methyl, ethyl, butyl, isobutyl, ethylhexyl, lauryl, stearyl, hydroxyethyl, and dimethylaminoethyl; acrylates including methyl, ethyl, butyl, isobutyl, ethylhexyl, lauryl, stearyl, and hydroxyethyl; glycidyl methacrylate; trialkoxysilane methacrylates, such as <NUM>-(methacryloxy)propyltrimethoxysilane and <NUM>-(methacryloxy)propyl-triethoxysilane, methacryloxymethyltrimethoxysilane, methacryloxymethyltriethoxysilane; acrylonitrile; <NUM>-isopropenyl-<NUM>-oxazoline; styrene; α-methylstyrene; vinyltoluene; dichlorostyrene; N-vinylpyrrolidinone, vinyl acetate, methacryloxypropyltrialkoxysilanes, methacryloxymethyltrialkoxysilanes and vinyl chloride.

In exemplary embodiments, the compatibilization agents used in the composition have glycidyl or acrylic functionality. In exemplary embodiments, the compatibilization agents used include maleic acid-modified or copolymerized polyolefins made to coexist with fumaric acid-modified or copolymerized polyolefins; acrylic-modified or copolymerized polyolefins that are made to coexist with fumaric acid-modified or copolymerized polyolefins; and/or silane grafted polyolefins.

In exemplary embodiments, the compatibilization agent used in the composition is a maleic anhydride (MAH) functionalized polyolefin. In exemplary embodiments, the compatibilization agent is a maleic anhydride functionalized polyolefin where the percentage of grafted MAH is from <NUM>% to <NUM>% (e.g., from <NUM>% to <NUM>%, from <NUM>% to <NUM>%, and/or from <NUM>% to <NUM>%).

The compositions of the present disclosure may be useful for preparing articles using known processes. For example, the compositions may be fabricated into parts, sheets or other article of manufacture, using any extrusion, calendering, blow molding, compression molding, injection molding, or thermoforming processes. The components of the composition may be fed to the process either pre-mixed, or the components may be fed directly into the process equipment, such as a converting extruder, such that the composition is formed therewithin. The compositions may be blended with another polymer, prior to fabrication of an article. Such blending may occur by any of a variety of conventional techniques, one of which is dry blending of pellets of the compositions with pellets of another polymer.

The compositions of the present disclosure can optionally include one or more additives and/or fillers. Non-limiting examples of additives and/or fillers include plasticizers, thermal stabilizers, light stabilizers (e.g., UV light stabilizers and absorbers), antioxidants, slip agents, process aids, optical brighteners, antistats, lubricants, catalysts, rheology modifiers, biocides, corrosion inhibitors, dehydrators, organic solvents, colorants (e.g., pigments and dyes), surfactants, demolding additives, mineral oil, antiblocking agents, nucleating agents, flame retardants, reinforcing fillers (e.g., glass, fibers, anti-scratch additives, talc, calcium carbonate, mica, glass fibers, whisker, etc.), processing aids, metal fibers, boron fibers, ceramic fibers, polymeric fibers, kaolin, glass, ceramic, carbon/polymeric microspheres, silica, mica, carbon fibers, clay, hemp fibers, and combinations thereof.

In exemplary embodiments, the composition has a melt flow rate of at least <NUM>/<NUM> minutes in accordance with ISO <NUM> at <NUM>, <NUM>.

In certain embodiments, the composition of the present disclosure comprises a flexural modulus (ISO <NUM>) from <NUM> MPa to <NUM> MPa (e.g., from <NUM> MPa to <NUM> MPa, from <NUM> MPa to <NUM> MPa, from <NUM> MPa to <NUM> MPa, and/or from <NUM> MPa to <NUM> MPa). In certain embodiments, the composition of the present disclosure comprises a flexural modulus (ISO <NUM>) of greater than <NUM> MPa, greater than <NUM> MPa, greater than <NUM> MPa, greater than <NUM> MPa, greater than <NUM> MPa, greater than <NUM> MPa, or greater than <NUM> MPa.

In certain embodiments, the composition of the present disclosure comprises a Charpy impact strength (ISO <NUM>-<NUM>) from <NUM> kJ/m<NUM> to <NUM> kJ/m<NUM>. In certain embodiments, the composition of the present disclosure comprises a Charpy impact strength (ISO <NUM>-<NUM>) of greater than <NUM> kJ/m<NUM>, greater than <NUM> kJ/m<NUM>, greater than <NUM> kJ/m<NUM>, greater than <NUM> kJ/m<NUM>, greater than <NUM> kJ/m<NUM>, greater than <NUM> kJ/m<NUM>, greater than <NUM> kJ/m<NUM>, greater than <NUM> kJ/m<NUM>, greater than <NUM> kJ/m<NUM>, or greater than <NUM> kJ/m<NUM>.

In certain embodiments, the composition of the present disclosure comprises a falling dart maximum force energy (ISO <NUM>-<NUM> (<NUM> edition)) from <NUM> J to <NUM> J. In certain embodiments, the composition of the present disclosure comprises a falling dart maximum force energy (ISO <NUM>-<NUM> (<NUM> edition)) of greater than <NUM> J, greater than <NUM> J, greater than <NUM> J, greater than <NUM> J, or greater than <NUM> J.

In certain embodiments, the composition of the present disclosure comprises a yield stress (ISO <NUM>) from <NUM> MPa to <NUM> MPa (e.g., from <NUM> MPa to <NUM> MPa, from <NUM> MPa to <NUM> MPa, from <NUM> MPa to <NUM> MPa, etc.).

In certain embodiments, the composition of the present disclosure comprises a yield strain (ISO <NUM>) from <NUM>% to <NUM>%.

In certain embodiments, the composition of the present disclosure comprises a stress at break (ISO <NUM>) from <NUM> MPa to <NUM> MPa (e.g., from <NUM> MPa to <NUM> MPa, from <NUM> MPa to <NUM> MPa, from <NUM> MPa to <NUM> MPa, from <NUM> MPa to <NUM> MPa, etc.).

In certain embodiments, the composition of the present disclosure comprises a strain at break (ISO <NUM>) from <NUM> MPa to <NUM> MPa (e.g., from <NUM> MPa to <NUM> MPa, from <NUM> MPa to <NUM> MPa, from <NUM> MPa to <NUM> MPa, from <NUM> MPa to <NUM> MPa, from <NUM> MPa to <NUM> MPa, from <NUM> MPa to <NUM> MPa, etc.).

In certain embodiments, the composition of the present disclosure comprises an average CLTE value of less than 5E-<NUM>/m/°C via machine direction (e.g., less than 4E-<NUM>/m/°C, less than <NUM>. 5E-<NUM>/m/°C, less than 3E-<NUM>/m/°C, less than <NUM>. 5E-<NUM>/m/°C, etc.).

In certain embodiments, the composition of the present disclosure comprises an average CLTE value of less than 8E-<NUM>/m/°C via transverse direction (e.g., less than <NUM>. 5E-<NUM>/m/°C, less than 7E-<NUM>/m/°C, less than <NUM>. 5E-<NUM>/m/°C, less than 6E-<NUM>/m/°C, less than <NUM>. 5E-<NUM>/m/°C, less than 5E-<NUM>/m/°C, less than <NUM>. 5E-<NUM>/m/°C, less than 4E-<NUM>/m/°C, less than <NUM>. 75E-<NUM>/m/°C, etc.).

Compositions of the present disclosure may have one, some, or all of the above-described properties regarding flexural modulus, Charpy impact strength, falling dart maximum force energy, yield stress, yield strain, stress at break, strain at break, and CLTE values.

Density is measured in accordance with ASTM D792 or ISO <NUM>. The results are reported in grams (g) per cubic centimeter, or g/cc.

Melt flow index is measured in accordance with ASTM D1238 or ISO <NUM> at <NUM>, <NUM>. The results are reported in grams/<NUM> minutes.

Melt flow rate is measured in accordance with ASTM D1238 or ISO <NUM> at <NUM>, <NUM>. The results are reported in grams/<NUM> minutes.

Charpy Impact Test: Impact performance is measured using a Pendulum Impact Tester Zwick <NUM>. Samples are first cut into appropriate samples, notched, and cooled for <NUM> hours (for temperatures lower than <NUM>). The tests are performed according to ISO <NUM>-<NUM> standard.

Flexural Modulus: Flexural modulus is determined using a Zwick Z010 and performed according to ISO <NUM> standard.

Falling Dart: Falling weight impact properties are determined using a Ceast Fractovis <NUM>/<NUM> and measured according to ISO <NUM>-<NUM> (<NUM> edition).

Tensile Properties: Tensile properties, including yield stress, yield strain, stress at break, and strain at break are measured in accordance with ISO <NUM>.

Coefficient of Linear Thermal Expansion (CLTE): CLTE is determined with a TMA3920 thermomechanical analyzer (TA Instruments) in compression mode at <NUM>/minute and a load of <NUM> N. The samples are annealed at <NUM> for <NUM> hours to remove the thermal and stress history.

Molecular weight distribution (MWD) is measured using Gel Permeation Chromatography (GPC). In particular, conventional GPC measurements are used to determine the weight-average (Mw) and number-average (Mn) molecular weight of the polymer and to determine the MWD (which is calculated as Mw/Mn). Samples are analyzed with a high-temperature GPC instrument. The method employs the well-known universal calibration method, based on the concept of hydrodynamic volume, and the calibration is performed using narrow polystyrene (PS) standards. The molecular weight determination is deduced by using narrow molecular weight distribution polystyrene standards (from Polymer Laboratories) in conjunction with their elution volumes. The equivalent polyethylene molecular weights are determined by using appropriate Mark-Houwink coefficients for polyethylene and polystyrene (as described by <NPL>)) to derive the following equation: <MAT>.

In this equation, a = <NUM> and b = <NUM> (as described in <NPL>)). Polyethylene equivalent molecular weight calculations were performed using VISCOTEK TriSEC software Version <NUM>.

Gel permeation chromatographic (GPC) system consists of either a Polymer Laboratories Model PL-<NUM> or a Polymer Laboratories Model PL-<NUM> instrument. The column and carousel compartments are operated at <NUM>. Three Polymer Laboratories <NUM>-micron Mixed-B columns are used. The solvent is <NUM>,<NUM>,<NUM> trichlorobenzene. The samples are prepared at a concentration of <NUM> grams of polymer in <NUM> milliliters of solvent containing <NUM> ppm of butylated hydroxytoluene (BHT). Samples are prepared by agitating lightly for <NUM> hours at <NUM>. The injection volume used is <NUM> microliters and the flow rate is <NUM>/minute.

Calibration of the GPC column set is performed with <NUM> narrow molecular weight distribution polystyrene standards with molecular weights ranging from <NUM> to <NUM>,<NUM>,<NUM>, arranged in <NUM> "cocktail" mixtures with at least a decade of separation between individual molecular weights. The standards are purchased from Polymer Laboratories (Shropshire, UK). The polystyrene standards are prepared at <NUM> grams in <NUM> milliliters of solvent for molecular weights equal to or greater than <NUM>,<NUM>,<NUM>, and <NUM> grams in <NUM> milliliters of solvent for molecular weights less than <NUM>,<NUM>,<NUM>. The polystyrene standards are dissolved at <NUM> with gentle agitation for <NUM> minutes. The narrow standards mixtures are run first and in order of decreasing highest molecular weight component to minimize degradation. The polystyrene standard peak molecular weights are converted to polyethylene molecular weights using the following equation (as described in <NPL>)): Mpolypropylene = <NUM>(Mpolystyrene).

Differential Scanning Calorimetry (DSC) results are determined using a TAI model Q1000 DSC equipped with an RCS cooling accessory and an autosampler. A nitrogen purge gas flow of <NUM>/min is used. The sample is pressed into a thin film and melted in the press at about <NUM>° C and then air-cooled to room temperature (<NUM>° C). <NUM>-<NUM> of material is then cut into a <NUM> diameter disk, accurately weighed, placed in a light aluminum pan (ca <NUM>), and then crimped shut. The thermal behavior of the sample is investigated with the following temperature profile. The sample is rapidly heated to <NUM>° C and held isothermal for <NUM> minutes in order to remove any previous thermal history. The sample is then cooled to -<NUM>° C at <NUM>° C/min cooling rate and held at -<NUM>° C for <NUM> minutes. The sample is then heated to <NUM>° C at <NUM>° C/min heating rate. The cooling (Tc) and second heating curves (Tm) are recorded.

The DSC melting peak is measured as the maximum in heat flow rate (W/g) with respect to the linear baseline drawn between -<NUM>° C and end of melting. The heat of fusion is measured as the area under the melting curve between -<NUM>° C and the end of melting using a linear baseline. DSC can also be used to measure the soft segment melting temperature, as discussed in <CIT>.

<NUM>C NMR spectroscopy is one of a number of techniques known in the art for measuring comonomer incorporation into a polymer. An example of this technique is described for the determination of comonomer content for ethylene/α-olefin copolymers in <NPL>)). The basic procedure for determining the comonomer content of an ethylene/olefin interpolymer involves obtaining a <NUM>C NMR spectrum under conditions where the intensity of the peaks corresponding to the different carbons in a sample is directly proportional to the total number of contributing nuclei in the sample. Methods for ensuring this proportionality are known in the art and involve allowance for sufficient time for relaxation after a pulse, the use of gated-decoupling techniques, relaxation agents, and the like. The relative intensity of a peak or group of peaks is obtained in practice from its computer-generated integral. After obtaining the spectrum and integrating the peaks, those peaks associated with the comonomer are assigned. This assignment can be made by reference to known spectra or literature, or by synthesis and analysis of model compounds, or by the use of isotopically labeled comonomers. The mole % comonomer can be determined by the ratio of the integrals corresponding to the number of moles of comonomer to the integrals corresponding to the number of moles of all of the monomers in the interpolymer, as described in the aforementioned Randall reference.

The soft segment weight percentage and hard segment weight percentage of and ethylene/olefin interpolymer of the present disclosure is determined by DSC, and mole % comonomer in the soft segment of an ethylene/olefin interpolymer of the present disclosure is determined by <NUM>C NMR spectroscopy and the methods described in <CIT>.

<NUM>C NMR Analysis: The samples are prepared by adding approximately <NUM> of a <NUM>/<NUM> mixture of tetrachloroethane-d<NUM>/orthodichlorobenzene to <NUM> sample in a <NUM> NMR tube. The samples are dissolved and homogenized by heating the tube and its contents to <NUM>° C. The data are collected using a JEOL Eclipse™ <NUM> spectrometer, Bruker <NUM> spectrometer, or a Varian Unity Plus™ <NUM> spectrometer, corresponding to a <NUM>C resonance frequency of <NUM>. The data is acquired using <NUM> transients per data file with a <NUM> second pulse repetition delay. To achieve minimum signal-to-noise for quantitative analysis, multiple data files are added together. The spectral width is <NUM>,<NUM> with a minimum file size of <NUM> data points. The samples are analyzed at <NUM>° C in a <NUM> broad band probe. The comonomer incorporation is determined using Randall's triad method (<NPL>).

DEZ levels (ppm) may be measured by standard industry procedure, such as mass balance or an XRF method.

Standard CRYSTAF Method: Branching distributions are determined by crystallization analysis fractionation (CRYSTAF) using a CRYSTAF <NUM> unit commercially available from PolymerChar, Valencia, Spain. The samples are dissolved in <NUM>,<NUM>,<NUM> trichlorobenzene at <NUM>° C (<NUM>/mL) for <NUM> hr and stabilized at <NUM>° C for <NUM> minutes. The sampling temperatures range from <NUM> to <NUM>° C at a cooling rate of <NUM>° C/min. An infrared detector is used to measure the polymer solution concentrations. The cumulative soluble concentration is measured as the polymer crystallizes while the temperature is decreased. The analytical derivative of the cumulative profile reflects the short chain branching distribution of the polymer.

The CRYSTAF peak temperature and area are identified by the peak analysis module included in the CRYSTAF Software (Version <NUM>. b, PolymerChar, Valencia, Spain). The CRYSTAF peak finding routine identifies a peak temperature as a maximum in the dW/dT curve and the area between the largest positive inflections on either side of the identified peak in the derivative curve. To calculate the CRYSTAF curve, the preferred processing parameters are with a temperature limit of <NUM>° C and with smoothing parameters above the temperature limit of <NUM>, and below the temperature limit of <NUM>.

Melt temperature, or "Tm" as used herein (also referred to as a melting peak in reference to the shape of the plotted DSC curve), is typically measured by the DSC (Differential Scanning Calorimetry) technique for measuring the melting points or peaks of polyolefins as described in <CIT>, wherein the Tm is the second heat melt temperature taken at a ramp rate of <NUM>/min and Tm is largest peak. The heat of fusion (Hf) (measured in Joules/gram, J/g) and the peak melting temperature are reported from the second heat curve. Peak crystallization temperature is determined from the cooling curve. Crystallization temperature, Tc, is determined from the DSC cooling curve as above except the tangent line is drawn on the high temperature side of the crystallization peak. Where this tangent intersects the baseline is the extrapolated onset of crystallization (Tc). It should be noted that many blends comprising two or more polyolefins will have more than one melting point or peak, and many individual polyolefins will comprise only one melting point or peak.

The following materials are principally used in the examples of the present disclosure:.

Based on these materials, formulations are prepared for the inventive and comparative examples of the present disclosure as seen in Tables <NUM> and <NUM>. All formulations in Tables <NUM> and <NUM> are compounded on a Buss Compounder MDK/E <NUM> with a single mixing screw (<NUM> L/D). The compounds are then injection molded as dog bones using an Injection Molding Boy 55E (BOY Machines, Inc. ) for mechanical property testing. The mechanical property test results are also provided in Tables <NUM> and <NUM>.

As seen when comparing Example A with Example B, the addition of carbon fibers to a polypropylene matrix allows for a high increase in flexural modulus but does not significantly improve the impact resistance properties (Charpy impact strength and falling dart impact energy) or the tensile properties (yield stress, stress at break, and strain at break). By contrast, as seen in Inventive Examples <NUM>-<NUM>, the addition of a thermoplastic polyolefin elastomer (TPE) to a polypropylene matrix containing carbon fibers surprisingly and unexpectedly allows for an increase in impact resistance properties (Charpy impact strength and falling dart impact energy) while limiting the decrease in flexural modulus. As seen in Inventive Example <NUM>, a particularly significant increase in impact resistance is unexpectedly demonstrated when the thermoplastic polyolefin elastomer added to the polypropylene matrix containing carbon fibers is an olefin block copolymer. These results are surprising and unexpected, since one of ordinary skill in the art would assume that the addition of carbon fibers to a composition would negatively impact the stiffness and toughness of the composition due to the fact that carbon fibers are very brittle and break down to small fibers after being compounded or injection molded into parts.

Furthermore, as seen in Inventive Examples <NUM>-<NUM>, the addition of a compatibilization agent to the polypropylene/carbon fiber composite containing a TPE unexpectedly and surprisingly allows for further improvement of the Charpy impact strength, as well as improvements in terms of tensile properties (e.g., yield stress, stress at break, and strain at break). As seen in Inventive Example <NUM>, increasing the concentration of carbon fibers to <NUM> weight percent in the presence of a compatibilization agent allows the increase of the Charpy impact strength and the flexural modulus, as well as certain tensile properties. Without the compatibilization agent, the Charpy impact strength decreases with higher concentration of carbon fibers due to the limited compatibility between carbon fibers and the polypropylene matrix.

The current state of the art of the automotive industry incorporates the use of glass fibers. In this regard, with respect to Comparative Examples C and D, it can observed that the use of carbon fibers in the present invention surprisingly showed better results in terms of both the impact resistance and the flexural modulus compared to use of glass fibers.

Accordingly, the present application discloses that the addition of a TPE surprisingly and unexpectedly allows for a significant increase of impact resistance of polypropylene/carbon fiber composites, while maintaining a high stiffness. Moreover, the addition of a compatibilization agent, such as polypropylene grafted with maleic anhydride, enhances the increase of Charpy impact strength, especially with a higher concentration of carbon fibers, and also enhances the tensile properties, such as yield stress, stress at break, and strain at break.

Further to the mechanical property testing, Coefficient of Linear Thermal Expansion (CLTE) tests were also performed according to the formulations of Tables <NUM> and <NUM>. All formulations in Tables <NUM> and <NUM> are compounded on a Buss Compounder MDK/E <NUM> with a single mixing screw (<NUM> L/D). The compounds are then injection molded as dog bones using an Injection Molding Boy 55E (BOY Machines, Inc. ) for CLTE testing. The CLTE test results are also provided in Tables <NUM> and <NUM>. MD refers to machine direction. TD refers to transverse direction.

A decrease of CLTE of polypropylene-based compounds is seen when carbon fibers are added, as seen when comparing Comparative Example B with Comparative Example E. A decrease in CLTE value is also seen when carbon fibers are used relative to use of glass fibers, as seen when comparing Comparative Example B with Comparative Example F and when comparing Inventive Example <NUM> with Comparative Example G.

Beyond this, Inventive Examples <NUM> and <NUM> (when compared to Comparative Examples B, E, F, and G) surprisingly and unexpectedly exhibit a significant decrease in CLTE value when an olefin block copolymer and carbon fibers are added to a polypropylene matrix. Accordingly, the present application discloses an unexpected synergetic effect of carbon fibers with olefin block copolymer in a polypropylene-based compound to achieve very low CLTE values.

Claim 1:
A composition comprising:
(A) from <NUM> wt% to <NUM> wt% of a propylene component including at least one propylene-based polymer having a propylene content of at least <NUM> wt%, based on the total weight of the propylene-based polymer, and a melt flow rate of at least <NUM>/<NUM> minutes as measured by ISO <NUM> at <NUM>/<NUM>;
(B) from <NUM> wt% to <NUM> wt% of a carbon fiber component; and
(C) from <NUM> wt% to <NUM> wt% of a thermoplastic polyolefin elastomer, wherein the thermoplastic polyolefin elastomer is an olefin block copolymer, and wherein the composition further comprises a flexural modulus of greater than <NUM> MPa, as determined using a Zwick Z010 and performed according to ISO <NUM> standard, a Charpy impact strength of greater than <NUM> kJ/m<NUM>, as determined using the method outlined in the description, and a falling dart maximum force energy of greater than <NUM> J, as determined using a Ceast Fractovis <NUM>/<NUM> and measured according to ISO <NUM>-<NUM> (<NUM> edition).