Heterophasic copolymers of polypropylene: Development, design principles, and future challenges

Comparing End-of-Life Vehicle (ELV) and Packaging-Based Recyclates as Components in Polypropylene-Based Compounds for Automotive Applications

Increasing recycled plastic content in cars to 25% by 2030 is one of the key measures for decarbonizing the automotive industry defined by the European Commission. This should include the recovery of plastics from end-of-life vehicles (ELVs), but such materials are hardly used in compounds today. To close the knowledge gap, two ELV recyclate grades largely based on bumper recycling were analyzed in comparison to a packaging-based post-consumer recyclate (PCR). The composition data were used to design polypropylene (PP) compounds for automotive applications with virgin base material and mineral reinforcement, which were characterized in relation to a commercial virgin-based compound. A compound with a 40 wt.-% ELV-based bumper recyclate can exceed one with just a 25 wt.-% packaging-based recyclate in terms of stiffness/impact balance. While the virgin reference can nearly be matched regarding mechanics, the flowability is not reached by any of the PCR compounds, making further development work necessary.

Ethylene Polymerization over Metal-Organic Framework-Supported Zirconocene Complexes

Metallocene immobilization onto a solid support helps to overcome the drawbacks of homogeneous metallocene complexes in the catalytic olefin polymerization. In this study, valuable insights have been obtained into the effects of pore size, linker composition, and surface groups of metal-organic frameworks (MOFs) on their role as support materials for metallocene-based ethylene polymerization catalysis. Three distinct Zn-based metal-organic frameworks (MOFs), namely, MOF-5, IRMOF-3, and ZIF-8, with different linkers have been activated with methylaluminoxane (MAO) and zirconocene complexes, followed by materials characterization and testing for ethylene polymerization. Characterization has been performed by multiple analytical tools, including X-ray diffraction (XRD), scanning electron microscopy (SEM), gel permeation chromatography (GPC), differential scanning calorimetry (DSC), and CO Fourier transform infrared (FT-IR) spectroscopy. It was found that the interactions between MOFs, MAO, and the zirconocene complex not only lead to both catalyst activation and deactivation but also result in the creation of multiple active sites. By alteration of the MOF support, it is possible to obtain polyethylene with different properties. Notably, ultrahigh molecular weight polyethylene (UHMWPE, M W = 5.34 × 106) was obtained using IRMOF-3 as support. This study reveals the potential of MOF materials as tunable porous supports for metallocene catalysts active in ethylene polymerization.

Polyolefin Blends with Selectively Crosslinked Disperse Phase Based on Silane-Modified Polyethylene

Polypropylene-based multiphase compositions with a disperse elastomer phase provide superior impact strength. Making this property indifferent to processing steps requires stabilization of the morphology of these materials. Various approaches have been tested over time, each of which shows limitations in terms of performance or applicability. Using polyethylene (PE) homo- and copolymers capable of silane-based crosslinking as modifiers was explored in the present study, which allows decoupling of the mixing and crosslinking processes. Commercial silane-copolymerized low-density PE (LD-PEX) from a high-pressure process and silane-grafted high-density PE (HD-PEX) were studied as impact modifiers for different types of PP copolymers, including non-modified reference PE grades, LDPE and HDPE. Blends based on ethylene-propylene random copolymers (PPR) and based on impact- (PPI) and random-impact (PPRI) copolymers show improvements of the stiffness-impact balance; however, to different degrees. While the absolute softest and most ductile compositions are achieved with the already soft PPRI copolymer base, the strongest relative effects are found for the PPR based blends. Modifiers with lower density are clearly superior in the toughening effect, with the LD-PEX including acrylate as second comonomer sticking out due to its glass transition around -40 °C. The impact strength improvement found in most compositions (except at very high content) results, however, not from the expected phase stabilization. For comparable systems, particle sizes are normally higher with crosslinking, probably because the process already starts during mixing. Thermoplastic processability could be retained in all cases, but the drop in melt flow rate limits the practical applicability of such systems.

Balancing the Strength-Impact Relationship and Other Key Properties in Polypropylene Copolymer-Natural CaSO4 (Anhydrite)-Filled Composites

To develop novel mineral-filled composites and assess their enhanced properties (stiffness, a good balance between mechanical strength and impact resistance, greater temperature stability), a high-impact polypropylene copolymer (PPc) matrix containing an elastomeric discrete phase was melt mixed with natural CaSO4 β-anhydrite II (AII) produced from gypsum rocks. First, in a prior investigation, the PPc composites filled with AII (without any modification) displayed enhanced stiffness, which is correlated with the relative content of the filler. The tensile and impact strengths dramatically decreased, especially at high filling (40 wt.%). Therefore, two key methods were considered to tune up their properties: (a) the ionomeric modification of PPc composites by reactive extrusion (REx) with zinc diacrylate (ZA), and (b) the melt mixing of PPc with AII surface modified with ethylenebis(stearamide) (EBS), which is a multifunctional processing/dispersant additive. The properties of composites produced with twin-screw extruders (TSEs) were deeply assessed in terms of morphology, mechanical, and thermal performance, including characterizations under dynamic mechanical solicitations at low and high temperatures. Two categories of products with distinct properties are obtained. The ionomeric modification by Rex (evaluated by FTIR) led to composites characterized by remarkable thermal stability, a higher temperature of crystallization, stronger interfacial interactions, and therefore noticeable mechanical properties (high tensile strength (i.e., 28 MPa), increased stiffness, moderate (3.3 kJ/m2) to good (5.0 kJ/m2) impact resistance) as well as advanced heat deflection temperature (HDT). On the other hand, the surface modification of AII with EBS facilitated the dispersion and debonding of microparticles, leading to composites revealing improved ductility (strain at break from 50% to 260%) and enhanced impact properties (4.3-5.3 kJ/m2), even at high filling. Characterized by notable mechanical and thermal performances, high whiteness, and a good processing ability, these new PPc-AII composites may be tailored to meet the requirements of end-use applications, ranging from packaging to automotive components.

Polymerization in the Borstar Polypropylene Hybrid Process: Combining Technology and Catalyst for Optimized Product Performance

Producing isotactic polypropylene (iPP) homo- and copolymers in a wide composition and property range according to customer demand requires perfect alignment between the process technology, catalyst system and polymer structure. The present review shows this for the Borstar® PP process, a hybrid process employing liquid bulk and gas phase stages, in an exemplary way. It starts with the process design and continues through two generations of Ziegler–Natta catalyst development history to the design of advanced multimodal random and multiphase copolymers. Essential elements of each of the three areas contributing to performance range are highlighted, and an outlook to future development is given.

Mechanical, Hydrophobic, and Barrier Properties of Nanocomposites of Modified Polypropylene Reinforced with Low-Content Attapulgite

Attapulgite (ATT) has never been used as a barrier additive in polypropylene (PP). As a filler, ATT should be added in high content to PP. However, that would result in increased costs. Moreover, the compatibility between ATT and the PP matrix is poor due to the lack of functional groups in PP. In this study, carboxylic groups were introduced to PP to form a modified polypropylene (MPP). ATT was purified, and a low content of it was added to MPP to prepare MPP/ATT nanocomposites. The analysis from FTIR indicated that ATT could react with MPP. According to the results of oxygen and water permeability tests, the barrier performance of the nanocomposite was optimal when the ATT content was 0.4%. This great improvement in barrier performance might be ascribed to the following three reasons: (1) The existence of ATT extended the penetration path of O₂ or H₂O molecules; (2) O₂ or H₂O molecules may be adsorbed and stored in the porous structure of ATT; (3) Most importantly, –COOH of MPP reacted with –OH on the surface of ATT, thereby the inner structure of the nanocomposite was denser, and it was less permeable to molecules. Therefore, nanocomposites prepared by adding ATT to MPP have excellent properties and low cost. They can be used as food packaging materials and for other related applications.

An Industrial Case for Polypropylene Nanocomposite Foams: Lightweight, Soundproof Exterior Automotive Parts

Lightweighting is a challenge for the automotive industry, and foaming is a key technology used to address this problem. A new practical approach is studied to regulate the cell formation of copolymer polypropylene (co-PP) by utilizing graphene nanoplatelets (xGnP) as a process aid during foam injection molding. The approach was designed to enable process freedom to tune part performance by adjusting the amount of xGnP masterbatch. Two different levels of 1–2 wt % xGnP and 0.25–0.35 wt % supercritical fluid (SCF) were investigated. Prepared samples were compared with samples prepared by the traditional method (twin-screw extrusion followed by foam injection molding). The nanocomposite with 2 wt % xGnP comparatively showed about twofold reduction in cell size magnitude. Although the increment in SCF amount resulted in a 47% and 122% enhancement in flexural modulus and strength, respectively, and a 45% loss in Izod unnotched impact strength, the cell size was prone to increasing with regard to low melt strength as compared to neat foams. In conclusion, a 12% weight reduction fulfilled the desired performance parameters in terms of mechanical and sound insulation by utilizing 2 wt % xGnP as a process aid.

Pressure- and Temperature-Dependent Crystallization Kinetics of Isotactic Polypropylene under Process Relevant Conditions

In this study, a non-nucleated homopolymer (HP) and random copolymer (RACO), as well as a nucleated HP and heterophasic copolymer (HECO) were investigated regarding their crystallization kinetics. Using pvT-measurements and fast scanning chip calorimetry (FSC), the crystallization behavior was analyzed as a function of pressure, cooling rate and temperature. It is shown that pressure and cooling rate have an opposite influence on the crystallization temperature of the materials. Furthermore, the addition of nucleating agents to the material has a significant effect on the maximum cooling rate at which the formation of α-crystals is still possible. The non-nucleated HP and RACO materials show significant differences that can be related to the sterically hindering effect of the comonomer units of RACO on crystallization, while the nucleated materials HP and HECO show similar crystallization kinetics despite their different structures. The pressure-dependent shift factor of the crystallization temperature is independent of the material. The results contribute to the description of the relationship between the crystallization kinetics of the material and the process parameters influencing the injection-molding induced morphology. This is required to realize process control in injection molding in order to produce pre-defined morphologies and to design material properties.

Crystallization of Random Metallocene-Catalyzed Propylene-Based Copolymers with Ethylene and 1-Hexene on Rapid Cooling

Propylene-based random copolymers with either ethylene or 1-hexene as comonomer, produced using a metallocene catalyst, were studied regarding their crystallization behaviors, with a focus on rapid cooling. To get an impression of processing effects, fast scanning chip calorimetry (FSC) was used in addition to the characterization of the mechanical performance. When comparing the comonomer type and the relation to commercial grades based on Ziegler-Natta-type catalysts, both an interaction with the catalyst-related regio-defects and a significant difference between ethylene and 1-hexene was observed. A soluble-type nucleating agent was found to modify the behavior, but to an increasingly lesser degree at high cooling rates.

Characterization of Composition and Structure-Property Relationships of Commercial Post-Consumer Polyethylene and Polypropylene Recyclates

The current efforts in moving closer towards a circular plastics economy puts massive pressure on recycled plastics, especially recycled polyethylene (rPE) and recycled polypropylene (rPP) to enter new markets. Their market penetration remained low so far, despite PE and PP constituting the largest share of plastic wastes. However, with the current imperative of more circularity comes a new focus on performance of recyclates. Hence, a detailed understanding of composition and structure–property relationships of post-consumer recyclates has to be developed. Five recycling companies from the Austrian and German markets were asked to supply their purest high-quality rPE and rPP grades. These were characterized by differential scanning calorimetry (DSC), thermo-gravimetric analysis (TGA), and Fourier-transform infrared (FTIR) spectroscopy, and micro-imaging. Technological characterization included density measurements, determination of the melt flow rate (MFR), and Charpy impact testing. All recyclates contained diverse contaminants and inclusions ranging from legacy fillers like calcium carbonate to polymeric contaminants like polyamides or polyolefin cross-contamination. The overall amount, size, and distribution of contaminants varied significantly among suppliers. Furthermore, first structure–property relationships for polyolefin recyclates that link inorganic content and polymeric purity with density and impact performance could be derived.

New Insights into Crystallization of Heterophasic Isotactic Polypropylene by Fast Scanning Chip Calorimetry

The crystallization kinetics of metallocene-catalyzed heterophasic isotactic polypropylene composed of a matrix of isotactic polypropylene (iPP) and rubbery particles made of random ethylene-propylene copolymers (EPC), often denoted as heterophasic iPP copolymers, was analyzed as a function of the cooling rate and supercooling in nonisothermal and isothermal crystallization experiments, respectively. Fast scanning chip calorimetry (FSC) allowed assessing crystallization at processing-relevant conditions, and variation of the content (0-39 wt %) and composition (0-35 wt % propylene counits) of the EPC particles revealed qualitatively new insight about mechanisms of heterogeneous crystal nucleation. For neat iPP homopolymer, the characteristic bimodal temperature dependence of the crystallization rate due to predominance of heterogeneous and homogeneous crystal nucleation at high and low temperatures, respectively, is reconfirmed. At high temperatures, in heterophasic iPP, the here studied ethylene-(C2)-rich EPC particles accelerate crystallization of the iPP-matrix, with the acceleration or nucleation efficacy correlating with the EPC-particle content. The crystallization time reduces by more than half in presence of 39 wt % EPC particles. An additional nucleating effect of the EPC particles on iPP-matrix crystallization is detected after their crystallization, suggesting that liquid/rubbery particles are less effective than solid/semicrystalline particles in affecting crystallization of the surrounding iPP-matrix. At low temperature, homogeneous crystal nucleation in the iPP-matrix outpaces all heterogeneous nucleation effects, and the matrix-crystallization rate is independent of the sample composition. The obtained results lead to the conclusion that the crystallization kinetics of iPP can be affected significantly by the content and composition of EPC particles, even towards superfast crystallizing iPP grades.

Crystalline Modification and Its Effects on Dielectric Breakdown Strength and Space Charge Behavior in Isotactic Polypropylene

Adding nucleating agents (NAs) is one of the most efficient ways to obtain improved mechanical, optical, and thermal properties of isotactic polypropylene (iPP). While it is well appreciated that electrical property is critically affected by crystalline modification, the role between them remains unclear. Here, we address this issue by incorporating commercial α-NA and β-NA into iPP, both of which exhibit strong nucleation ability, e.g., reducing the size of crystalline agglomerates from 45.3 μm (Pure-iPP) to 2.5 μm (α-iPP) and 7.6 μm (β-iPP), respectively. Mechanical testing results show that while β-modification decreases the tensile strength a little, it does enhance the elongation at break (200%) and toughness (25.3% higher), relative to its unfilled counterparts. Moreover, a well-dispersed β-iPP system obtains a comprehensive improvement of electrical properties, including dielectric breakdown strength, space charge suppression, and internal field distortion under a high external field (-100 kV/mm) due to newly-generated deep charge trapping sites. This crystalline modification strategy is attractive for future development of many engineering insulating polymers.

Combined effect of α-nucleating agents and glass fiber reinforcement on a polypropylene composite: a balanced approach

An approach by combining α-nucleating agents and glass fibre reinforcement for improving the comprehensive mechanical properties of polypropylene composite: a balanced approach.

Influence of the HDPE molecular weight and content on the morphology and properties of the impact polypropylene copolymer/HDPE blends

The properties of the polyolefins blends depend not only on composition but also on morphology.