Polyolefin impact copolymers

Polypropylene, a homopolymer polyolefin engineering plastic provides excellent chemical resistance, purity and it is the lightest of all commercial plastics. PP offers innovative solutions to many challenges that face the automotive industry today. Its low density compared to traditional materials significantly contributes to fuel economy and reduced material costs. Its excellent noise, vibration, and harshness (NVH) properties contribute to enhanced passenger comfort. Thus, PP has become the most important thermoplastic material in automobile industry. PP homopolymers, random copolymers, and impact copolymers are used in products such as automotive parts and battery cases, carpeting, electrical insulation, and fabrics. 

A hot melt adhesive composition made from polypropylene copolymer or polypropylene impact copolymer, a polyolefin elastomer, a low density polyethylene, a tackilying resin, a plasticizer, and a nucleating agent The 0.2 to 1 wt% of nucleating agent is... 

The polyolefin block copolymers are lower in cost. Their suggested applications (74) include wire and cable insulation, replacements for PVC and styrenic block copolymers, and blends with polypropylene, either to improve impact resistance or as the soft phase in a hard polymer/elastomer combination. Processing conditions are similar to those for polyethylene, and thermal stability is excellent. 

Fig. 26. Qualitative compatison of substrate materials for optical disks (187) An = birefringence IS = impact strength BM = bending modulus HDT = heat distortion temperature Met = metallizability WA = water absorption Proc = processibility. The materials are bisphenol A—polycarbonate (BPA-PC), copolymer (20 80) of BPA-PC and trimethylcyclohexane—polycarbonate (TMC-PC), poly(methyl methacrylate) (PMMA), uv-curable cross-linked polymer (uv-DM), cycHc polyolefins (CPO), and, for comparison, glass.

In the preceding sections, our discussion has been limited to softer grade elastomer-plastic vulcanizates. Commercial interest, however, also centers on another major family of polymer blends, semi-rigid impact resistant polyolefins. Thus, we report some of our findings on PRP triblock copolymer and EVA rubber blends without... 

Obviously, there exists severe interplastics competition, e.g. PP vs. ABS, clarified PP vs. PS, PA, PVC, HDPE and PS (Table 10.7). A wide range of cross-linked and thermoplastic elastomer applications, from footware to automotive parts and toothbrushes, are adopting new metallocene-catalysed polyolefin elastomers (POEs). These low-density copolymers of ethylene and octene were first accepted as impact modifiers for TPOs, but now displace EPDM, (foamed) EVA, flexible PVC, and olefinic thermoplastic vulcanisates (TPVs). Interpolymer competition may also result from... 

The crystallization kinetics of commercial polyolefins is to a large extent determined by the chain microstructure [58-60]. The kinetics and the regime [60] of the crystallization process determine not only the crystalline content, but also the structure of the interfaces of the polymer crystals (see also Chapter 7). This has a direct bearing on the mechanical properties like the modulus, toughness, and other end use properties of the polymer in fabricated items such as impact resistance and tear resistance. Such structure-property relationships are particularly important for polymers with high commercial importance in terms of the shear tonnage of polymer produced globally, like polyethylene and polyethylene-based copolymers. It is seen that in the case of LLDPE, which is... 

Standard Oil Co. claims the use of polyisobutylene as a plasticizer for polyvinyl acetate. Copolymers of isobutylene with vinyl ethers and other monomers are mentioned in several patents. For synthetic rubbers, oligomers of butadiene are claimed. Rubberlike polyolefins (10 to 50% is sufficient) are used extensively for plasticizing phenolic resins to increase impact strength. 

Diblock copolymers, especially those containing a block chemically identical to one of the blend components, are more effective than triblocks or graft copolymers. Thermodynamic calculations indicate that efficient compat-ibilisation can be achieved with multiblock copolymers [47], potentially for heterogeneous mixed blends. Miscibility of particular segments of the copolymer in one of the phases of the bend is required. Compatibilisers for blends consisting of mixtures of polyolefins are of major interest for recyclates. Random poly(ethylene-co-propylene) is an effective compatibiliser for LDPE-PP, HDPE-PP or LLDPE-PP blends. The impact performance of PE-PP was improved by the addition of very low density PE or elastomeric poly(styrene-block-(ethylene-co-butylene-l)-block styrene) triblock copolymers (SEBS) [52]. 

As block copolymers are still rather expensive materials, it may be advantageous to use them as additives to important industrial polymers. In this domain, possibilities are extremely numerous and diverse. They include an improvement of chemical properties such as resistence to degradation agents, or rheological properties such as adhesion of vinylic paints, high impact properties of conventional thermoplastics, or a compatibilization of polyolefins, polystyrene and poly(vinyl chloride) allowing the reuse of polymeric waste products. The above examples illustrate the great intrinsic potential of block copolymers in the quest of new materials with specific properties. 

PVC can be blended with numerous other polymers to give it better processability and impact resistance. For the manufacture of food contact materials the following polymerizates and/or polymer mixtures from polymers manufactured from the above mentioned starting materials can be used Chlorinated polyolefins blends of styrene and graft copolymers and mixtures of polystyrene with polymerisate blends butadiene-acrylonitrile-copolymer blends (hard rubber) blends of ethylene and propylene, butylene, vinyl ester, and unsaturated aliphatic acids as well as salts and esters plasticizerfrec blends of methacrylic acid esters and acrylic acid esters with monofunctional saturated alcohols (Ci-C18) as well as blends of the esters of methacrylic acid butadiene and styrene as well as polymer blends of acrylic acid butyl ester and vinylpyrrolidone polyurethane manufactured from 1,6-hexamethylene diisocyanate, 1.4-butandiol and aliphatic polyesters from adipic acid and glycols. 

The following TPs are the main thermoforming materials processed high-impact and high-heat PS, HDPE, PP, PVC, ABS, CPET, PET, and PMMA. Other plastics of lesser usage are transparent styrene-butadiene block copolymers, acrylics, polycarbonates, cellulosics, thermoplastic elastomers (TPE), and ethylene-propylene thermoplastic vulcanizates. Coextruded structures of up to seven layers include barriers of EVAL, Saran, or nylon, with polyolefins, and/or styreneics for functional properties and decorative aesthetics at reasonable costs.239-241... 

Copolymers of ethylene with a-olefins, such as the short-chain branched LLDPE (linear low-density polyethylene) impact materials or the EPD (ethylene-propylene-diene copolymer) rubbers represent major percentages of the total polyolefin production, due to their desirable mechanical properties. Solid-state MgCl2-supported Ziegler-Natta catalysts however, have unfavourable reactivity... 

Polystyrene is one of the most widely used thermoplastic materials ranking behind polyolefins and PVC. Owing to their special property profile, styrene polymers are placed between commodity and speciality polymers. Since its commercial introduction in the 1930s until the present day, polystyrene has been subjected to numerous improvements. The main development directions were aimed at copolymerization of styrene with polar comonomers such as acrylonitrile, (meth)acrylates or maleic anhydride, at impact modification with different rubbers or styrene-butadiene block copolymers and at blending with other polymers such as polyphenylene ether (PPE) or polyolefins. 

Impact Polystyrene Polycarbonate Polyolefin/Nylon Alloy Polypropylene SAN Copolymer... 

It is worthwhile to note that chemistry plays a major role in the morphology and control of mechanical properties in complex systems like PPE blends with crystalline polymers, such as polyolefins, polyamides (PA) and polyesters (18). The amount of copolymer formed during the reactive extrusion between functionalised PPE and PA has a significant effect on the impact-strength of blends. The latter levels off only above 10% of copolymer. 

Several approaches to compatibilizing PPE blends with commercial polyolefins (polypropylene, etc.) have been reported in the literature [Lee, 1990 Kirkpatrick, 1989]. However, no commercial blends of PPE/polyolefins have been offered to date. CompatibUization and impact modification of PPE/polypropylene can be achieved by choosing a selected type of styrene-ethylene/butylene-styrene block copolymer and PPE of low molecular weight [Akkapeddi and VanBuskirk, 1992]. 

Blends of polyolefins (e.g., HPDE/LDPE, LDPE/ ethylene copolymers, PP/EPDM, PP/HDPE/EPDM, HDPE/butyl rubber) have been commercial since the late 1960 s and early 1970 s. Specific film formulations were commonly based on polyolefin blends to achieve the proper balance of processing, environmental stress crack resistance, modulus, toughness, cling, transparency, filler acceptance, printability, tear resistance, shrinkage characteristics, and permeability. Ethylene-propylene mbber (EPR, EPDM) was commonly incorporated into polypropylene as an impact modifier at moderate levels and as a flexibilizer at high levels. One of... 

The second growing trend is the impact modification of polyolefin blends using styrenic block copolymers, which are known to be clear, strong, have low glass transition, compatible with PP, form interpenetrating polymer networks, and very efficient in contrast to maleic anhydride-grafted polyolefins. 

Isotactic PP and ICP can be physically blended with EPR to adjust the modulus and the impact resistance. Recently, new types of polyolefin copolymers have been developed to replace EPR with higher compatibility with PP using metallocene catalysts. These polyolefin copolymers will be discussed in Section 8.4. Nitta et al. (7) compared the PP/EPR blends with different EPR in terms of My, MWD, and crystallinity. The different compatibility of EPR with PP creates different morphologies, which are shown in Fig. 8.5. 

Practically, some of the above polyolefin copolymers have already been used to blend with PP in applications such as car bumpers and impact elastomeric goods. Although ethylene-propylene random copolymer has been the main component for such... 

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