Search

KR-20260066175-A - Flame-retardant polypropylene composition

KR20260066175AKR 20260066175 AKR20260066175 AKR 20260066175AKR-20260066175-A

Abstract

The present invention relates to a polypropylene composition (C) comprising a mixed-plastic polypropylene blend (PPB), a flame retardant (FR), and an anti-dripping agent (AD), and an article comprising the polypropylene composition (C).

Inventors

  • 기사스 안토니오스
  • 스톡라이터 울프강
  • 칼린 수잔 마가렛
  • 코스타 프란시스 레니

Assignees

  • 보레알리스 게엠베하

Dates

Publication Date
20260512
Application Date
20240926
Priority Date
20230927

Claims (15)

  1. i) 30.0 to 90.0 weight% mixed-plastic polypropylene blend (PPB), ii) 10.0 to 40.0 weight% of flame retardant (FR), iii) 0.01 to 30.0 weight% of an anti-dripping agent (AD), and iv) 0 to 25.0 wt% of propylene polymer (PP) having a melt flow rate MFR 2 (230°C, 2.16 kg) of at least 15.0 g/10 min as determined according to ISO 1133 As a polypropylene composition (C) comprising, Polypropylene composition (C), all weight contents based on the total weight of the polypropylene composition (C).
  2. In paragraph 1, · UL94 rating of V-0 after 48 hours of conditioning according to Condition Part 1 in the UL94 flame retardancy test; · UL94 rating of V-0 after 168 hours of conditioning according to Condition Part 2 in the UL94 flame retardancy test Having one or more or all of the characteristics of, Polypropylene composition (C), each having an injection-molded sample with a length of 125±5 mm, a width of 13.0±0.5 mm, and a thickness of 1.5 mm.
  3. In paragraph 1 or 2, · A tensile modulus of at least 1250 MPa, e.g. 1250 to 3000 MPa, preferably 1500 to 2500 MPa, more preferably 1650 to 2250 MPa; · Tensile strength of at least 12 MPa, e.g. 12 to 40 MPa, preferably 15 to 35 MPa, more preferably 17 to 30 MPa; · Tensile stress at break of at least 2.3%, e.g. 2.3% to 7.5%, preferably 2.5% to 7.0%, more preferably 2.7% to 6.0% Having one or more or all of the characteristics of, Polypropylene composition (C), all determined according to ISO 527-1A at 23℃.
  4. In any one of paragraphs 1 through 3, · Charpy notched impact strength at 23°C of at least 1.0 kJ/ m² , e.g. 1.0 to 10.0 kJ/ m² , preferably 1.2 to 8.5 kJ/ m² , more preferably 1.5 to 7.5 kJ/ m² , when determined according to ISO 179-1 / 1eA at 23°C; · Melt flow rate MFR 2 at 2.16 kg and 230°C, determined according to ISO 1133, of 2.5 to 20.0 g/10 min, preferably 3.0 to 15.0 g/10 min, more preferably 4.0 to 12.5 g/10 min. A polypropylene composition (C) having one or more or all of the characteristics of
  5. In any one of paragraphs 1 through 4, Mixed-plastic polypropylene blend (PPB) · Crystalline fraction (CF) content in the range of 80.0 to 96.0 wt%, preferably 82.5 to 95.5 wt%, as determined by CRYSTEX QC analysis; and · Content of the soluble fraction (SF) in the range of 4.0 to 20.0 wt%, preferably 4.5 to 17.5 wt%, as determined by CRYSTEX QC analysis Having, · The crystalline fraction (CF) has an ethylene content (C2(CF)) in the range of 1.0 to 15.0 wt%, preferably 1.5 to 12.5 wt%, when determined by FT-IR spectroscopy corrected by quantitative 13 C-NMR spectroscopy; · The crystalline fraction (CF) has an intrinsic viscosity (iV(CF)) in the range of 0.9 to 2.1 dl/g, preferably 1.0 to 2.0 dl/g, more preferably 1.1 to 1.9 dl/g; · The above-mentioned soluble fraction (SF) has an ethylene content (C2(SF)) in the range of 15.0 to 40.0 wt%, preferably 20.0 to 37.5 wt%, when determined by FT-IR spectroscopy corrected by quantitative 13 C-NMR spectroscopy; · The above-mentioned soluble fraction (SF) has an intrinsic viscosity (iV(SF)) in the range of 0.9 to 2.2 dl/g, preferably 1.0 to 2.1 dl/g, more preferably 1.1 to 2.0 dl/g, a polypropylene composition (C).
  6. In any one of paragraphs 1 through 5, Mixed-plastic polypropylene blend (PPB) · Melt flow rate MFR 2 at 230℃ and 2.16 kg, determined according to ISO 1133, of 15.0 to 40.0 g/10 min, preferably 16.5 to 35.0 g/10 min, more preferably 17.5 to 30.0 g/10 min; · Density of 900 to 1030 kg/ m³ when determined according to ISO 1183, preferably 905 to 1020 kg/ m³ , more preferably 910 to 1010 kg/ m³ ; · Limonene content of 1 to 250 mg/ m³ when determined using solid-phase microextraction (HS-SPME-GC-MS); · Tensile modulus of 1,000 to 1,750 MPa, preferably 1,100 to 1,600 MPa, when determined according to ISO 527-2; · Charpy notched impact strength at 23°C of 3.0 to 7.5 kJ/ m² , preferably 4.0 to 7.0 kJ/ m² , when determined according to ISO 179-1/1eA at 23°C A polypropylene composition (C) having one or more or all of the characteristics of
  7. In any one of paragraphs 1 through 6, A polypropylene composition (C) wherein the flame retardant (FR) is a nitrogen-containing flame retardant (FR), more preferably comprising a first nitrogen-containing phosphate (FR1) and a second nitrogen-containing phosphate (FR2), optionally the weight ratio between the first nitrogen-containing phosphate (FR1) and the second nitrogen-containing phosphate (FR2) is in the range of 60:40 to 40:60, the first nitrogen-containing phosphate (FR1) is preferably melamine polyphosphate, and the second nitrogen-containing phosphate (FR2) is preferably piperazine pyrophosphate.
  8. In any one of paragraphs 1 through 7, A polypropylene composition (C) in which the flame retardant (FR) is halogen-free.
  9. In any one of paragraphs 1 through 8, i) a mixed-plastic polypropylene blend (PPB) of 55.0 to 90.0 weight%, preferably 62.5 to 84.0 weight%, more preferably 66.5 to 79.0 weight%; ii) 10.0 to 40.0 weight%, 15.0 to 35.0 weight%, more preferably 20.0 to 32.5 weight% of flame retardant (FR), iii) an antidrip agent comprising 0.01 to 5.0 weight%, preferably 0.05 to 2.5 weight%, more preferably 0.1 to 1.5 weight% of a halogenated polyolefin, preferably a fluorinated polyolefin, most preferably poly(tetrafluoroethylene) (PFTE), iv) 0 wt% of propylene polymer (PP) having a melt flow rate MFR 2 (230°C, 2.16 kg) of at least 15.0 g/10 min as determined according to ISO 1133, and v) 0 to 15.0 weight%, preferably 0 to 12.5 weight%, more preferably 0 to 10.0 weight% of additive (ADD) Includes, Polypropylene composition (C), all weight contents based on the total weight of the polypropylene composition (C).
  10. In any one of paragraphs 1 through 8, i) a mixed-plastic polypropylene blend (PPB) of 30.0 to 80.0 weight%, preferably 35.0 to 70.0 weight%, more preferably 40.0 to 60.0 weight%; ii) 10.0 to 40.0 weight%, 15.0 to 35.0 weight%, more preferably 20.0 to 32.5 weight% of flame retardant (FR), iii) an antidrip agent which is 10.0 to 30.0 weight%, preferably 12.5 to 27.5 weight%, more preferably 15.0 to 25.0 weight% of high melt strength polypropylene (HMS-PP), iv) 0 wt% of propylene polymer (PP) having a melt flow rate MFR 2 (230°C, 2.16 kg) of at least 15.0 g/10 min as determined according to ISO 1133; and v) 0 to 15.0 wt%, preferably 0 to 12.5 wt%, more preferably 0 to 10.0 wt% additive (ADD) Includes, Polypropylene composition (C), all weight contents based on the total weight of the polypropylene composition (C).
  11. In any one of paragraphs 1 through 8, i) a mixed-plastic polypropylene blend (PPB) of 30.0 to 69.0 weight%, preferably 35.0 to 60.0 weight%, more preferably 40.0 to 50.0 weight%; ii) 10.0 to 40.0 weight%, 15.0 to 35.0 weight%, more preferably 20.0 to 32.5 weight% of flame retardant (FR), iii) an antidrip agent which is 10.0 to 30.0 weight%, preferably 12.5 to 27.5 weight%, more preferably 15.0 to 25.0 weight% of high melt strength polypropylene (HMS-PP), iv) a propylene polymer (PP) having a melt flow rate MFR 2 (230°C, 2.16 kg) of at least 15.0 g/10 min, determined according to ISO 1133, in an amount of 11.0 to 25.0 wt%, preferably 12.5 to 22.5 wt%, more preferably 15.0 to 20.0 wt%; and v) 0 to 15.0 wt%, preferably 0 to 12.5 wt%, more preferably 0 to 10.0 wt% additive (ADD) Includes, Polypropylene composition (C), all weight contents based on the total weight of the polypropylene composition (C).
  12. In Article 10 or Article 11, A polypropylene composition (C) that does not contain an amount of fluoropolymer exceeding 0.5 wt%, more preferably 0.1 wt%, even more preferably 0.01 wt%, e.g. 0.001 wt%, and most preferably fluoropolymer-free polypropylene composition (C).
  13. In any one of paragraphs 1 through 12, Propylene polymer (PP) is a heterophase propylene copolymer (HECO), and heterophase propylene copolymer (HECO) is · A melt flow rate MFR 2 (230℃, 2.16 kg) in the range of at least 45.0 g/10 min, e.g. 45.0 to 300 g/10 min, preferably 60.0 to 200 g/10 min, more preferably 80.0 to 120 g/ 10 min, as determined according to ISO 1133; · Xylene cold-soluble fraction (XCS) in the range of 7.0 to 25.0 weight% based on the total weight of the heterophase propylene copolymer (HECO) Having one or more or all of the characteristics of, The xylene-soluble fraction (XCS) of heterophase propylene copolymer (HECO) is · Comonomer content exceeding 35.0 mol%, and/or · Intrinsic viscosity (IV) of less than 3.5 dl/g when measured according to ISO 1628/1 (in decalin at 135°C) Polypropylene composition (C) having
  14. In any one of paragraphs 1 through 13, A polypropylene composition (C) in which the total amount of a mixed-plastic polypropylene blend (PPB), a flame retardant (FR), an anti-drip agent (AD), and optionally a propylene polymer (PP) together constitutes at least 85.0 weight% of the polypropylene composition (C).
  15. An article comprising a polypropylene composition (C) according to any one of claims 1 to 14.

Description

Flame-retardant polypropylene composition The present invention relates to a polypropylene composition comprising a mixed-plastic polypropylene blend (PPB), a flame retardant (FR), and an anti-dripping agent (AD), and an article comprising the polypropylene composition. Manufacturers of electric motors and power electronic equipment components have used housings made of steel or die-cast aluminum. However, as many components are now actively cooled, plastic solutions exist as a possibility for lightweight structures. Some of these existing alternatives are primarily based on PC/ABS or polyamide, which are engineering plastics that are expensive to produce and come with a high CO2 footprint. Among these, one of the mandatory requirements for electronic equipment enclosures is to achieve a UL94 V-0 flame retardant rating at a thickness of less than 1.5 mm. The materials that meet these requirements are most likely metals, halogenated flame-retardant-reinforced polymers, polymers with inherently flame-retardant properties, or non-halogenated flame-retardant-reinforced polymers, such as PC/ABS flame-retardant systems. In these flame-retardant systems, the high load of flame-retardant additives leads to degradation in material performance and processing problems. Additionally, anti-drip agents are generally required to prevent dripping during combustion. Propylene polymers can also be applied as base polymers for flame-retardant systems. Generally speaking, glass fibers are used in combination with polypropylene to achieve specific mechanical properties (e.g., stiffness). The main disadvantages of glass fiber reinforced polypropylene, however, are dimensional instability in the fiber direction and high twisting, particularly when high-flow polypropylene is used as the base polymer. Low twisting, however, is critical, especially for high-precision parts (e.g., cell holders). In recent years, polymer waste has been recognized as a major environmental and economic problem. Consequently, efforts are being made to recycle polymer waste and utilize recycled polymers in upcycling applications. However, when virgin and recycled materials are mixed, a decrease in mechanical performance is often observed. WO 2023/006797 A1 discloses a flame-retardant polypropylene composition comprising high melt strength polypropylene made of virgin components as a drip agent, which meets the requirements of UL94 V-0 and exhibits low warping while maintaining high mechanical properties. Surprisingly, when the virgin propylene polymer used in the composition of WO 2023/006797 A1 was replaced with a mixed-plastic polypropylene blend (mixed-plastic polypropylene blend, PPB) from post-consumer waste in an amount of up to 90 weight percent of the total flame-retardant polypropylene composition, it was found that, contrary to expectations, no loss was observed in mechanical properties and in UL94 testing. The present invention i) 30.0 to 90.0 weight% mixed-plastic polypropylene blend (PPB), ii) 10.0 to 40.0 weight% of flame retardant (FR), iii) 0.01 to 30.0 weight% of an antidrip agent (AD), and iv) 0 to 25.0 wt% of propylene polymer (PP) having a melt flow rate MFR 2 (230°C, 2.16 kg) of at least 15.0 g/10 min as determined according to ISO 1133 The invention relates to a polypropylene composition (C) comprising, All weight contents are based on the total weight of the polypropylene composition (C). In addition, the present invention relates to an article comprising a polypropylene composition (C) as described above or below. definition Unless otherwise defined, all technical and scientific terms used herein have the same meaning as generally understood by a person skilled in the art to which the present invention pertains. Although any method and material similar or equivalent to that described herein may actually be used for testing the present invention, preferred materials and methods are described herein. In describing and claiming the present invention, the following terms are used according to the definitions set forth below. Unless otherwise explicitly indicated, the use of terms such as "a," "an," etc., refers to one or more. Blended plastics are defined as the presence of small amounts of compounds not typically found in virgin polypropylene blends, such as polystyrene, polyamide, polyester, wood, paper, limonene, aldehydes, ketones, fatty acids, metals, and/or long-term degradation products of stabilizers. Virgin polypropylene blends refer to blends derived directly from the production process without the use of intermediates. By definition, "mixed plastic" may be equated with detectable amounts of polystyrene and/or polyamide-6 and/or limonene and/or fatty acids. Therefore, blended plastics, unlike virgin polymers, can originate from both post-consumer waste and industrial waste. Post-consumer waste refers to objects that have completed at least their first use cycle (or life cycle), that is, objects that have already served their