Ultra-low density polypropylene plastic compound

• US 10,590,269 B2
• Filed: 04/20/2018
• Issued: 03/17/2020
• Est. Priority Date: 04/20/2018
• Status: Active Grant

• Current Assignee: Ford Global Technologies, LLC (Ford Motor Company)
• Original Assignee: Ford Global Technologies, LLC (Ford Motor Company)
• Inventors: Dellock, Paul Kenneth, Gall, Richard, Salter, Stuart, Karmo, Talat, Myszka, Joseph
• Primary Examiner(s): Mullis, Jeffrey C
• Application Number:
  US15/958,633
• Publication Number:
  US 20190322849A1
• Time in Patent Office: 697 Days
• CPC Class Codes: C08K 7/14 Glass
• CPC Class Codes: C08K 7/20 Glass
• CPC Class Codes: C08L 2205/025 containing two or more polymers of the same hierarchy C08L, and differing only in parameters such as density, comonomer content, molecular weight, structure
• CPC Class Codes: C08L 2205/03 containing three or more polymers in a blend
• CPC Class Codes: C08L 2205/035 containing four or more polymers in a blend
• CPC Class Codes: C08L 2205/06 having improved processability or containing aids for moulding methods
• CPC Class Codes: C08L 23/12 Polypropene
• CPC Class Codes: C08L 23/16 Elastomeric ethene-propene or ethene-propene-diene copolymers, e.g. EPR and EPDM rubbers

Abstract

A composite material is provided. The composite material includes a polypropylene blend, at least one additive, and at least one structural filler in an amount between 1.0 wt. % and 10.0 wt. %. The polypropylene blend includes a homopolymer polypropylene having a minimum ASTM D638 tensile strength of 4,000 psi in an amount between 40 wt. % and 70 wt. %, a high crystallinity homopolymer polypropylene having a minimum ASTM D638 tensile strength of 6,000 psi in an amount between 5 wt. % and 30 wt. %, and an impact copolymer having a rubber content greater than zero and less than 30 wt. %, the impact copolymer being in an amount between 3 wt. % and 10 wt. %.

Claims

1. A composite material comprising:

a polypropylene blend comprising;

a homopolymer polypropylene having a minimum ASTM D638 tensile strength of 4,000 psi in an amount of 61.0 wt. %;

a high crystallinity homopolymer polypropylene having a minimum ASTM D638 tensile strength of 6,000 psi in an amount of 21.0 wt. %;

an impact copolymer having a rubber content greater than zero and less than 30 wt. %, the impact copolymer being in an amount of 5.0 wt. %; and

a tie-layer resin in an amount of 1.5 wt. %;

structural fillers comprising glass bubbles in an amount of 4.0 wt. % and chopped fiberglass in an amount of 5.0 wt. %; and

additives comprising a UV stabilizer in an amount of 0.7 wt. %;

an antioxidant in an amount of 0.3 wt. %;

a color additive in an amount of 1.25 wt. %; and

a viscosity agent in an amount of 0.25 wt. %.

2. The composite material according to claim 1, wherein the additives further comprise a coupling agent, zinc carboxylate salt, and a flame retardant.

3. The composite material according to claim 1, wherein the fibers of the chopped fiberglass have a 14 micron diameter.

4. The composite material according to claim 1, wherein no talc is contained within the composite material.

5. The composite material according to claim 1, wherein the homopolymer polypropylene is a recycled material.

6. A part formed from the composite material according to claim 1 having mechanical properties of:

a tensile yield strength of at least 35 MPa;

a yield elongation of at least 3.5%;

a tensile modulus of at least 2.0 GPa;

a flexural modulus of at least 2.0 GPa;

a notched IZOD at 24°

C. of at least 5.5 kJ/m²; and

a heat deformation temperature at 1.8 MPa of at least 58°

C.

7. A vehicle leaf screen comprising the composite material according to claim 1.

8. An injection moldable composite material for use in a structural component comprising:

a polypropylene blend comprising;

a homopolymer polypropylene having a minimum ASTM D638 tensile strength of 4,000 psi in an amount between 40 wt. % and 70 wt. %;

a high crystallinity homopolymer polypropylene having a minimum ASTM D638 tensile strength of 6,000 psi in an amount between 5 wt. % and 30 wt. %; and

an impact copolymer having a rubber content greater than zero and less than 30 wt. % in an amount between 2 wt. % and 10 wt. %;

a structural filler comprising glass fibers in the amount of 5.0 wt. % and hollow glass spheres in the amount of 4.0 wt. %; and

at least one additive.

9. The injection moldable composite material according to claim 8, wherein the additive is selected from the group consisting of a coupling agent, a viscosity agent, zinc carboxylate salt, an antioxidant, a UV stabilizer, color, and a flame retardant.

10. The injection moldable composite material according to claim 8, wherein no talc is contained within the composite material.

11. A structural component manufactured from the injection moldable composite material according to claim 8 and having the following mechanical properties:

a tensile yield strength of at least 35 MPa;

a yield elongation of at least 3.5%;

a tensile modulus of at least 2.0 GPa;

a flexural modulus of at least 2.0 GPa;

a notched IZOD at 24°

C. of at least 5.5 kJ/m²;

a heat deformation temperature at 1.8 MPa of at least 58°

C.; and

a melt flow rate of at least 16.9 g/10 min as measured under a 2.16 kg load at 230°

C.

12. The injection moldable composite material according to claim 8, wherein the homopolymer polypropylene is a recycled material.

13. The injection moldable composite material according to claim 8, wherein the additive comprises:

a UV stabilizer in an amount of 0.7 wt. %;

an antioxidant in an amount of 0.3 wt. %;

a color additive in an amount of 1.25 wt. %; and

a viscosity agent in an amount of 0.25 wt. %.

14. An injection moldable composite material for use in a structural component comprising:

a polypropylene blend comprising;

a homopolymer polypropylene having a minimum ASTM D638 tensile strength of 4,000 psi in an amount between 40 wt. % and 70 wt. %;

a high crystallinity homopolymer polypropylene having a minimum ASTM D638 tensile strength of 6,000 psi in an amount between 5 wt. % and 30 wt. %; and

an impact copolymer having a rubber content greater than zero and less than 30 wt. %, the impact copolymer being in an amount between 5.0 wt. % and 12.0 wt. %;

chopped glass fibers in an amount between 1.0 and 10.0 wt. % and hollow glass spheres in an amount between 1.0 and 10.0 wt. %

a coupling agent in an amount between 1.5 wt. % and 3 wt. %,

a viscosity agent in an amount between 0.15 wt. % and 0.50 wt. %;

an antioxidant in an amount between 0.1 wt. % and 0.5 wt. %;

a UV stabilizer in an amount between 0.1 wt. % and 1.5 wt. %; and

color additive in an amount between 1.0 wt. % and 3.0 wt. %.

15. The injection moldable composite material according to claim 14, wherein no talc is contained within the composite material.