BR112020004348B1 - REINFORCED POLYMER COMPOSITION - Google Patents

Abstract

It is a reinforced polymeric composition comprising polypropylene (PP), polar modified polypropylene (PMP) and carbon fibers (CF).

Description

[0001] The present invention is directed to a reinforced polymeric composition comprising a polypropylene (PP), a polar modified polypropylene (PMP) and carbon fibers (CF). Additionally, the present invention is directed to an article comprising the reinforced polymeric composition.

[0002] Reinforced polymer compositions are widely used. However, in addition to the requirements for mechanical and optical properties, light weight has become an important requirement for many applications. In general, there are two possibilities to support these requirements, namely, one decreases the density of the material or one increases the hardness of the material. Regarding increased stiffness, it can generally be obtained by adding fibers as a reinforcing material to the polymer. For example, glass fibers are widely used as reinforcing materials because of their good processability, excellent properties and low cost. Furthermore, carbon fibers are well known as a reinforcing material because of their low density in combination with high stiffness. However, the addition of fibers as reinforcing material typically results in an overall increase in density and results in inferior optical properties, so that a sufficiently light weight material that has well-balanced mechanical and optical properties is just difficult to obtain. Additionally, in order to increase subsequent processing efficiency, it is desirable to decrease the viscosity and injection pressure of the reinforced polymeric composition. Document EP3095819 describes compositions that also contain carbon fibers that do not have rather low tensile moduli. Document EP 3095818 relates to a carbon fiber composite of limited melt flow rate and limited stiffness-impact balance. Document EP3095820 discloses carbon fiber-containing compositions that have a balance of impact resistance-elongation and tensile strength at break. Document US2012/0238688 also refers to compositions containing carbon fiber.

[0003] Consequently, industries search for a composite material that meets the demand requirements of well-balanced mechanical and optical properties, in particular stiffness and impact resistance with reduced surface defects, which are known as flow marks, tiger strips or flow lines, in light weight in combination with a low viscosity.

[0004] The finding of the present invention consists in using a specific polypropylene, in combination with a polar modified polypropylene and carbon fibers in order to achieve well-balanced mechanical and optical properties, in particular, stiffness and impact resistance with reduced surface defects. , which are known as flow marks, tiger strips or flow lines, in light weight in combination with a low viscosity.

[0005] In a first aspect, a composition is described - a tensile modulus measured in accordance with ISO 527-2 in the range of 8500 to 11500 MPa, - a Charpy Impact Strength measured in accordance with ISO 179-leU:2000 at 23 °C in the range of 30 to 50 kJ/m2 and - a tensile elongation at break measured in accordance with ISO 527-2 in the range of 2.0 to 5.0 %, wherein the polymeric composition (PC) comprises (a) 55 to 95 parts by weight of a polypropylene (PP) composition; (b) 2.5 to 10 parts by weight of a polar modified polypropylene (PMP); (c) 2.5 to 35 parts by weight of carbon fibers (CF); wherein the parts by weight are based on the total parts by weight of compounds (a), (b) and (c).

[0006] The polypropylene (PP) composition may comprise (a) a first propylene homopolymer (PPH-1); and/or (b) a second propylene homopolymer (PPH-2); and/or (c) and a third propylene homopolymer (PPH-3); wherein the first propylene homopolymer (PPH-1), the second propylene homopolymer (PPH-2) and the third propylene homopolymer (PPH-3) differ from each other in their melt flow rates MFR2 (230 °C , 2.16 kg of load).

[0007] Propylene homopolymer (HPP-1) can have a melt flow rate MFR2 (230 ° C, 2.16 kg) measured according to ISO 1133 in the range of 1.0 to 45 g/10 min.

[0008] Propylene homopolymer (HPP-2) can have an MFR2 melt flow rate (230 °C, 2.16 kg) measured according to ISO 1133 in the range of 50 to 190 g/10 min.

[0009] Propylene homopolymer (HPP-3) can have a melt flow rate MFR2 (230 °C, 2.16 kg) measured according to ISO 1133 in the range of 200 to 800 g/10 min.

[0010] In one embodiment, the polypropylene (PP) composition may comprise: (a1) 2.5 to 22.5 parts by weight of propylene homopolymer (HPP-1); (a2) 55 to 95 parts by weight of propylene homopolymer (HPP-2); and (a3) 2.5 to 22.5 parts by weight of propylene homopolymer (HPP-3); based on total parts by weight of compounds (a1), (a2) and (a3).

[0011] The polypropylene (PP) composition may additionally comprise a random ethylene copolymer (RPE).

[0012] In one embodiment, the polypropylene (PP) composition may comprise: (b1) 6 to 19 parts by weight of propylene homopolymer (HPP-1); (b2) 43 to 85 parts by weight of propylene homopolymer (HPP-2); (b3) 6 to 19 parts by weight of propylene homopolymer (HPP-3); and (b4) 6 to 19 parts by weight of random ethylene copolymers (RPE); based on the total parts by weight of compounds (b1), Petition 870200029206, dated 03/04/2020, p. 12/85 (b2), (b3) and (b4).

[0013] The polypropylene (PP) composition may additionally comprise a heterophasic propylene copolymer (HECO).

[0014] In one embodiment, the polypropylene (PP) composition may comprise: (c1) 5 to 25 parts by weight of propylene homopolymer (HPP-1); (c2) 15 to 50 parts by weight of propylene homopolymer (HPP-2); (c3) 5 to 25 parts by weight of propylene homopolymer (HPP-3); and (c4) 20 to 60 parts by weight of heterophasic propylene copolymer (HECO); based on total parts by weight of compounds (b1), (b2), (b3) and (b4).

[0015] The polymeric composition (PC) may comprise polypropylene (PP) in an amount of at least 55% by weight, based on the total weight of the polymeric composition (PC).

[0016] The polymeric composition (PC) may comprise polar modified polypropylene (PMP) in an amount of at least 2.5% by weight, based on the total weight of the polymeric composition (PC).

[0017] The polymeric composition (PC) may comprise the polymeric composition (PC) comprising carbon fibers (CF) in an amount of at least 2.5% by weight, based on the total weight of the polymeric composition (PC) .

[0018] The polymeric composition (PC) may comprise polypropylene (PP) and polar modified polypropylene (PMP) which are comprised in an amount of at least 57.5% by weight, preferably, in an amount of at least 66 % by weight, more preferably, in an amount of at least 68% by weight, even more preferably, in an amount of at least 75% by weight based on the total weight of the polymeric composition (PC).

[0019] The polymeric composition (PC) may comprise polypropylene (PP), polar modified polypropylene (PMP) and carbon fibers (CF) in an amount of at least 60% by weight, preferably in an amount of at least 71% by weight, more preferably, in an amount of at least 79% by weight, even more preferably, in an amount of at least 89% by weight, based on the total weight of the polymeric composition (PC).

[0020] The polymeric composition (PC) may additionally have (a) a tensile strength measured in accordance with ISO 5272 of at least 60 MPa and/or (b) a flexural modulus measured in accordance with ISO 178 of at least 5000 MPa. In one embodiment, the polymeric composition (PC) does not comprise (c) any fibers other than carbon fibers (CF); and/or (d) any polymers other than polypropylene (PP) and polar modified polypropylene (PMP).

[0021] In one embodiment, the polymeric composition (PC) does not comprise any polymer other than propylene homopolymer (HPP-1), propylene homopolymer (HPP-2) and propylene homopolymer (HPP-3).

[0022] In one embodiment, the polymeric composition (PC) does not comprise any other polymer other than the propylene homopolymer (HPP-1), the propylene homopolymer (HPP-2), the propylene homopolymer (HPP-3) and the elastomeric copolymer (E).

[0023] In one embodiment, the polymeric composition (PC) does not comprise any other polymer other than the propylene homopolymer (HPP-1), the propylene homopolymer (HPP-2), the propylene homopolymer (HPP-3) and the heterophasic propylene copolymer (HECO).

[0024] A second aspect is directed to an article comprising a polymeric composition (PC) according to the first aspect.

The Polymeric Composition (PC)

[0025] The present invention is directed to a polymeric composition (PC) comprising a composition of polypropylene (PP), a polar modified polypropylene (PMP) and carbon fibers (CF).

[0026] The polymeric composition (PC) may comprise (a) the polypropylene (PP) composition in an amount in the range of 55 to 95 parts by weight, preferably in the range of 63 to 92 parts by weight, more preferably , in the range of 65 to 87 parts by weight; and/or (b) polar modified polypropylene (PMP) in an amount in the range of 2.5 to 10 parts by weight, preferably in the range of 3.0 to 7.0 parts by weight, more preferably in the range from 3.0 to 6.0 parts by weight; and/or (c) carbon fibers (CF) in an amount in the range of 2.5 to 35 parts by weight, preferably in the range of 5.0 to 30 parts by weight, more preferably in the range of 10 to 29 parts by weight; based on total parts by weight of polypropylene (PP), polar modified polypropylene (PMP) and carbon fibers (CF).

[0027] In one embodiment, the polymeric composition (PC) comprises polypropylene (PP) in an amount in the range of 55 to 95 parts by weight, polar modified polypropylene (PMP) in an amount in the range of 2.5 to 10 parts by weight and carbon fibers (CF) in an amount ranging from 2.5 to 35 parts by weight; based on total parts by weight of polypropylene (PP), polar modified polypropylene (PMP) and carbon fibers (CF).

[0028] In one embodiment, the polypropylene (PC) composition comprises polypropylene (PP) in an amount in the range of 63 to 92 parts by weight, polar modified polypropylene (PMP) in an amount in the range of 3.0 to 7.0 parts by weight and carbon fibers (CF) in an amount ranging from 2.5 to 35 parts by weight; based on total parts by weight of polypropylene (PP), polar modified polypropylene (PMP) and carbon fibers (CF).

[0029] In one embodiment, the polymeric composition (PC) comprises polypropylene (PP) in an amount in the range of 65 to 87 parts by weight, polar modified polypropylene (PMP) in an amount in the range of 3.0 to 6 .0 parts by weight and carbon fibers (CF) in an amount ranging from 5.0 to 30 parts by weight; based on total parts by weight of polypropylene (PP), polar modified polypropylene (PMP) and carbon fibers (CF).

[0030] In one embodiment, the polymeric composition (PC) comprises polypropylene (PP) in an amount in the range of 65 to 87 parts by weight, polar modified polypropylene (PMP) in an amount in the range of 3.0 to 6 .0 parts by weight and carbon fibers (CF) in an amount ranging from 10 to 29 parts by weight; based on total parts by weight of polypropylene (PP), polar modified polypropylene (PMP) and carbon fibers (CF).

[0031] In one embodiment, the polymeric composition (PC) comprises polypropylene (PP) in an amount in the range of 55 to 95% by weight, polar modified polypropylene (PMP) in an amount in the range of 2.5 to 10 % by weight and carbon fibers (CF) in an amount ranging from 2.5 to 35% by weight; based on the total weight of the polymeric composition (PC).

[0032] In one embodiment, the polymeric composition (PC) comprises polypropylene (PP) in an amount ranging from 63 to 92% by weight, polar modified polypropylene (PMP) in an amount ranging from 3.0 to 7. .0% by weight and carbon fibers (CF) in an amount ranging from 5.0 to 30% by weight; based on the total weight of the polymeric composition (PC).

[0033] In one embodiment, the polymeric composition (PC) comprises polypropylene (PP) in an amount in the range of 65 to 87% by weight, polar modified polypropylene (PMP) in an amount in the range of 3.0 to 6 .0% by weight and carbon fibers (CF) in an amount ranging from 10 to 29% by weight; based on the total weight of the polymeric composition (PC).

[0034] The present polymeric composition (PC) has a high melt flow rate to reduce pressure during the injection molding process. Consequently, the polymeric composition (PC) has an MFR2 melt flow rate (230 °C, 2.16 kg) measured according to ISO 1133 of 20 to 30 g/10 min.

[0035] The polymeric composition (PC) has a tensile modulus measured according to ISO 527-2 in the range of 8500 to 11500 MPa.

[0036] The polymeric composition (PC) may have a tensile strength measured in accordance with ISO 527-2 of at least 60 MPa, preferably at least 80 MPa, such as in the range of 60 to 130 MPa, preferably, in the range of 80 to 115 MPa.

[0037] The polymeric composition (PC) has a Charpy Impact Resistance measured in accordance with ISO 179-leU:2000 at 23 °C in the range of 30 to 50 kJ/m2.

[0038] The polymeric composition (PC) has a tensile elongation at break measured in accordance with ISO 527-2 in the range of 2.0 to 5.0%.

[0039] The polymeric composition (PC) may have a flexural modulus measured in accordance with ISO 178 of at least 5000 MPa, preferably at least 6500 MPa, as in the range of 5000 to 11000 MPa, preferably in the range of 6500 to 9500 MPa.

[0040] The polymeric composition (PC) according to the present invention has a melt flow rate MFR2 (230 ° C, 2.16 kg) measured according to ISO 1133 in the range of 20 to 30 g/10 min, a tensile modulus measured in accordance with ISO 527-2 in the range of 8500 to 11500 MPa, a Charpy Impact Strength measured in accordance with ISO 179-leU:2000 at 23 °C in the range of 30 to 50 kJ/m2 and a tensile elongation at break measured in accordance with ISO 527-2 in the range of 2.0 to 5.0 %.

[0041] It is observed that the polymeric composition has a heat deformation temperature (HDT) measured in accordance with ISO 75-2 of at least 90 °C, preferably at least 120 °C, more preferably , at least 150 °C, such as in the range of 90 to 190 °C, preferably in the range of 120 to 170 °C.

[0042] Preferably, polypropylene (PP) is the only polypropylene present in the polymeric composition (PC). In one embodiment, polypropylene (PP) is the only polypropylene present in the polymeric composition (PC).

[0043] Preferably, polar modified polypropylene (PMP) is the only polar modified polypropylene present in the polymeric composition (PC). In one embodiment, polar modified polypropylene (PMP) is the only polar modified polypropylene present in the polymeric composition (PC).

[0044] In a preferred embodiment, the polymeric composition (PC) does not comprise polymers other than polypropylene (PP) and polar modified polypropylene (PMP) in an amount that exceeds 10% by weight, preferably, in an amount that exceeds 5% by weight, more preferably in an amount exceeding 2.5% by weight, even more preferably in an amount exceeding 0.8% by weight, based on the weight of the composition Petition 870200029206, dated 04/ 03/2020, page. 19/85 polymeric (PC). If an additional polymer is present, such polymer is typically a polymeric carrier material (PCM) for additives.

[0045] Preferably, polypropylene (PP) and polar modified polypropylene (PMP) are the only polymers present in the polymeric composition (PC). In one embodiment, polypropylene (PP) and polar modified polypropylene (PMP) are the only polymers present in the polymeric composition (PC).

[0046] Preferably, carbon fibers (CF) are the only fibers present in the polymeric composition (PC). In one embodiment, the polymeric composition (PC) does not comprise fibers selected from the group consisting of glass fibers, metallic fibers, mineral fibers, ceramic fibers and mixtures thereof. In one embodiment, the polymeric composition (PC) does not comprise fibers obtained from an inorganic material.

[0047] Thus, in a preferred embodiment, the polymeric composition (PC) consists of polypropylene (PP), polar modified polypropylene (PMP) and carbon fibers (CF). However, it should be noted that this does not exclude situations in which additives (AD) are present, as will be explained in detail below.

[0048] The polymeric composition (PC) preferably contains an alpha-nucleating agent as part of the additives (AD). Even more preferably, the present invention is free of beta-nucleating agents.

[0049] The nucleating agent is preferably selected from the group consisting of (i) salts of monocarboxylic acids and acids Petition 870200029206, of 03/04/2020, p. 20/85 polycarboxylic acids, for example, sodium benzoate or aluminum tert-butylbenzoate, and (ii) dibenzylidene sorbitol (for example, 1.3: 2.4 dibenzylidene sorbitol) and C1-C8-alkyl-substituted dibenzylidene sorbitol derivatives, such as methyldibenzylidene sorbitol , ethyldibenzylidene sorbitol or dimethyldibenzylidene sorbitol (e.g., 1,3:2,4 di(methylbenzylidene) sorbitol), or substituted nonitol derivatives such as 1,2,3,-trideoxy-4,6:5,7-bis-0- [(4-propylphenyl)methylene]-nonitol, and (iii) salts of phosphoric acid diesters, for example, sodium 2,2'-methylenebis(4,6,-di-tert-butylphenyl)phosphate or hydroxy-bis [2,2'-methylene-bis(4,6-di-t-butylphenyl)aluminum phosphate], and (iv) vinylcycloalkane polymer and vinylalkane polymer, and (v) mixtures thereof.

[0050] Such additives are generally commercially available and are described, for example, in "Plastic Additives Handbook", 5th edition, 2001 by Hans Zweifel.

[0051] Most preferably, the alpha-nucleating agent is part of the polypropylene (PP) and, therefore, of the polymeric composition (PC). Accordingly, the alpha nucleating agent content of polypropylene (PP) is preferably up to 5.0% by weight, based on the weight of the dibenzylidene sorbitol (e.g., 1.3: 2.4 dibenzylidene sorbitol). , dibenzylidene sorbitol derivative, preferably dimethyldibenzylidene sorbitol (e.g. 1,3:2,4 di(methylbenzylidene) sorbitol), or substituted nonitol derivatives such as 1,2,3,-trideoxy-4,6:5,7 -bis-0-[(4-propylphenyl)methylene]-nonitol, vinylcycloalkane polymer, vinylalkane polymer and mixtures thereof.

[0052] In a preferred embodiment, the polypropylene (PP) and thus the polymeric composition (PC) contains a vinylcycloalkane, such as vinylcyclohexane (VCH), polymer and/or vinylalkane polymer, such as the alpha- nucleation. Preferably, in this embodiment, the polypropylene (PP) contains a vinylcycloalkane, such as vinylcyclohexane (VCH), polymer and/or vinylalkane polymer, preferably vinylcyclohexane (VCH). Preferably, the vinylcycloalkane is vinylcyclohexane (VCH) polymer which is introduced into the polypropylene (PP) and thereby into the polymeric composition (PC) by BNT technology. More preferably, in this preferred embodiment, the amount of vinylcycloalkane, such as vinylcyclohexane (VCH), polymer and/or vinylalkane polymer, more preferably vinylcyclohexane (VCH) polymer, in the polypropylene (PP) is not more than 500 ppm, more preferably 1 to 200 ppm, most preferably 5 to 100 ppm, and the amount of vinylcycloalkane, such as vinylcyclohexane (VCH), polymer and/or vinylalkane polymer, most preferably , of vinylcyclohexane (VCH) polymer, in polypropylene (PP) is no more than 500 ppm, more preferably 1 to 200 ppm, most preferably 5 to 100 ppm. Accordingly, it is therefore preferred that the polymeric composition (PC) contains not more than 500 ppm, more preferably 0.1 to 200 ppm, most preferably 0.2 to 100 ppm, of vinylcycloalkane, such as vinylcyclohexane (VCH) polymer.

[0053] In relation to BNT technology, reference is made to international applications WO 99/24478, WO 99/24479 and, particularly, WO 00/68315. According to this technology, a catalyst system, preferably a Ziegler-Natta procatalyst, can be modified by polymerization of a vinyl compound in the presence of the catalyst system, which comprises, in particular, the Ziegler-Natta procatalyst. special, an external donor and a cocatalyst, wherein the vinyl compound has the formula: CH2=CH-CHR3R4 wherein R3 and R4 together form a 5- or 6-membered aromatic, saturated or unsaturated ring or independently represent an alkyl group that comprises 1 to 4 carbon atoms, and the modified catalyst is used for preparing polypropylene (PP) according to this invention.

[0054] The polymerized vinyl compound acts as an alpha-nucleating agent. The weight ratio between vinyl compound and solid catalyst component in the catalyst modification step is preferably up to 5 (5:1), preferably up to 3 (3:1), most preferably 0 .5 (1:2) to 2 (2:1). The most preferred vinyl compound is vinylcyclohexane (VCH).

[0055] The nucleating agent can be introduced as a master batch. In this case, a master batch contains a nucleating agent, which is preferably a polymeric nucleating agent, more preferably an alpha-nucleating agent, most preferably a vinylcycloalkane, such as vinylcyclohexane (VCH), polymer and/or vinylalkane polymer, preferably vinylcyclohexane (VCH) polymer, as defined above or below, in an amount of not more than 500 ppm, more preferably, from 1 to 200 ppm, and, even more preferably 5 to 100 ppm, based on master batch weight. In this embodiment, more preferably, said master batch is present in an amount of no more than 10.0% by weight, more preferably no more than 5.0% by weight, and most preferably no more than 3 .5% by weight, where the preferred master batch amount is 1.5 to 3.5% by weight, based on the total weight of the polypropylene (PP). Most preferably, the master batch preferably comprises a polymer that has been nucleated according to BNT technology.

Polypropylene (PP)

[0056] It is observed that the polymeric composition (PC) has well-balanced mechanical and optical properties in combination with a low viscosity. In order to obtain these properties it is an essential requirement to include polypropylene (PP) composition.

[0057] The polypropylene (PP) composition may comprise at least one propylene homopolymer, at least one propylene copolymer, at least one ethylene copolymer and/or mixtures thereof.

[0058] If the polypropylene (PP) composition comprises propylene homopolymer, that propylene homopolymer can be multimodal with respect to this molecular weight distribution curve, which is the graph of the molecular weight fraction as a function of its molecular weight .

[0059] In one embodiment, the polypropylene (PP) composition comprises a propylene homopolymer that is multimodal with respect to its molecular weight distribution curve. In this case, the polypropylene composition may comprise at least two, preferably three, propylene homopolymers selected from propylene homopolymer (HPP-1), propylene homopolymer (HPP-2) and propylene homopolymer (HPP-2). ), wherein the propylene homopolymer (PPH-1), the propylene homopolymer (PPH-2), and the propylene homopolymer (PPH-3) differ from each other in their MFR2 melt flow rates (230 °C, 2.16 kg of load).

[0060] The expression "propylene homopolymer" refers to a polypropylene consisting essentially, that is, of more than 99.7% by weight, even more preferably, of at least 99.8% by weight, in units of propylene, based on the weight of the propylene homopolymer. In a preferred embodiment, only propylene units are detectable in the propylene homopolymer.

[0061] The expression "propylene copolymer" refers to polypropylene copolymerized with monomers not derived from propylene. The term "propylene copolymer" encompasses random propylene copolymers, heterophase propylene copolymers and mixtures thereof.

[0062] The term "ethylene copolymer" refers to ethylene copolymerized with non-ethylene-derived monomers. The term "ethylene copolymer" encompasses random ethylene copolymers, heterophase ethylene copolymers and mixtures thereof.

[0063] The term "heterophasic propylene copolymer" is intended for a propylene copolymer comprising a homo or random copolymer matrix component of propylene and an elastomeric copolymer component of propylene with one or more of ethylene and C4-C12 copolymers alpha-olefin or an ethylene elastomeric copolymer component with one or more C4-C12 alpha-olefin copolymers, wherein the elastomeric (amorphous) copolymer component is dispersed in said propylene homo- or random copolymer matrix component. The term "heterophasic" indicates that at least one elastomeric copolymer is (finely) dispersed in a matrix. In other words, the at least one elastomeric copolymer forms inclusions in the matrix. Thus, the matrix contains (finely) dispersed inclusions that are not part of the matrix and said inclusions contain at least one elastomeric copolymer. The term "inclusion" should indicate that the matrix and inclusion form different phases in the heterophasic propylene copolymer, wherein said inclusions are, for example, visible by high-resolution microscope, such as electron microscope or scanning force microscope.

[0064] The expression "random" indicates that the comonomers of random propylene copolymers (RPP) and random ethylene copolymers (RPE) are randomly distributed in the propylene-derived units in the case of a random propylene copolymer (RPP) and the units derived from ethylene in the case of a random ethylene copolymer (RPE). The term random is understood according to IUPAC (Glossary of basic terms in polymer science; IUPAC recommendations 1996).

[0065] Where the expression "comprising" is used in the present description and in the claims, it does not exclude other elements. For the purposes of the present invention, the expression "consisting of" is considered as a preferred embodiment of the expression "comprising". If, hereinafter, a group is defined as comprising at least a certain number of modalities, it should also be understood as revealing a group preferably consisting of only those modalities.

[0066] The polypropylene (PP) composition may preferably comprise: (a) a first propylene homopolymer (PPH-1); and/or (b) a second propylene homopolymer (PPH-2); and/or (c) a third propylene homopolymer (PPH-3); wherein the first propylene homopolymer (PPH-1), the second propylene homopolymer (PPH-2), and the third propylene homopolymer (PPH-3) differ from each other in their melt flow rates MFR2 (230 °C , 2.16 kg of load).

[0067] In this embodiment, it is observed that the polymeric composition (PC) does not comprise any other polymer in an amount that exceeds 5.0% by weight, more preferably, that exceeds 3.0% by weight, even more preferably , which exceeds 1.0% by weight, even more preferably, which exceeds 0.8% by weight, based on the total weight of the polymeric composition (PC), in addition to the first propylene homopolymer (PPH-1), the second propylene homopolymer (PPH-2), the third propylene homopolymer (PPH-3) and polar modified polypropylene (PMP). In particular, it is noted that the polymeric composition (PC) does not comprise any other polymer other than the first propylene homopolymer (PPH-1), the second propylene homopolymer (PPH-2), the third propylene homopolymer (PPH-3 ) and polar modified polypropylene (PMP).

[0068] The polypropylene (PP) composition may preferably comprise: (a) a first propylene homopolymer (PPH-1); or (b) a second propylene homopolymer (PPH-2); or (c) a third propylene homopolymer (PPH-3).

[0069] In this embodiment, it is observed that the polymeric composition (PC) does not comprise any other polymer in an amount that exceeds 5.0% by weight, more preferably, that exceeds 3.0% by weight, even more preferably, which exceeds 1.0% by weight, even more preferably, which exceeds 0.8% by weight, based on the total weight of the polymeric composition (PC), in addition to the first propylene homopolymer (PPH-1), of the second propylene homopolymer (PPH-2), third propylene homopolymer (PPH-3) and polar modified polypropylene (PMP). In particular, it is noted that the polymeric composition (PC) does not comprise any other polymer other than the first propylene homopolymer (PPH-1), the second propylene homopolymer (PPH-2), the third propylene homopolymer (PPH-3 ) and polar modified polypropylene (PMP).

[0070] In one embodiment, polypropylene (PP) preferably comprises a first propylene homopolymer (PPH-1) and a second propylene homopolymer (PPH-2), wherein the first propylene homopolymer (PPH -1) and the second propylene homopolymer (PPH-2) differ from each other in their MFR2 melt flow rates (230 °C, 2.16 kg load).

[0071] In this embodiment, it is observed that the polymeric composition (PC) does not comprise any other polymer in an amount that exceeds 5.0% by weight, more preferably, that exceeds 3.0% by weight, even more preferably, which exceeds 1.0% by weight, even more preferably, which exceeds 0.8% by weight, based on the total weight of the polymeric composition (PC), in addition to the first propylene homopolymer (PPH-1), of the second propylene homopolymer (PPH-2) and polar modified polypropylene (PMP). In particular, it is noted that the polymeric composition (PC) does not comprise any other polymer other than the first propylene homopolymer (PPH-1), the second propylene homopolymer (PPH-2) and the polar modified polypropylene (PMP).

[0072] In one embodiment, polypropylene (PP) preferably comprises a first propylene homopolymer (PPH-1) and a third melt flow MFR2 (230 ° C, 2.16 kg load).

[0073] In this embodiment, it is observed that the polymeric composition (PC) does not comprise any other polymer in an amount that exceeds 5.0% by weight, more preferably, that exceeds 3.0% by weight, even more preferably, which exceeds 1.0% by weight, even more preferably, which exceeds 0.8% by weight, based on the total weight of the polymeric composition (PC), in addition to the first propylene homopolymer (PPH-1), of the third homopolymer of propylene (PPH-3) and polar modified polypropylene (PMP). In particular, it is noted that the polymeric composition (PC) does not comprise any other polymer other than the first propylene homopolymer (PPH-1), the third propylene homopolymer (PPH-3), and the polar modified polypropylene (PMP).

[0074] In one embodiment, polypropylene (PP) preferably comprises a second propylene homopolymer (PPH-2) and a third propylene homopolymer (PPH-3), wherein the second propylene homopolymer (PPH -2) and the third propylene homopolymer (PPH-3) differ from each other in their MFR2 melt flow rates (230 °C, 2.16 kg load).

[0075] In this embodiment, it is observed that the polymeric composition (PC) does not comprise any other polymer in an amount that exceeds 5.0% by weight, more preferably, that exceeds 3.0% by weight, even more preferably , which exceeds 1.0% by weight, even more preferably, which exceeds 0.8% by weight, based on the total weight of the polymeric composition (PC), in addition to the second propylene homopolymer (PPH-2), the third propylene homopolymer (PPH-3) and polar modified polypropylene (PMP). In particular, it is noted that the polymeric composition (PC) does not comprise any other polymer other than the second propylene homopolymer (PPH-2), the third propylene homopolymer (PPH-3) and the polar modified polypropylene (PMP).

[0076] In one embodiment, polypropylene (PP) preferably comprises a first propylene homopolymer (PPH-1) a second propylene homopolymer (PPH-2) and a third propylene homopolymer (PPH-3) , wherein the first propylene homopolymer (PPH-1), the second propylene homopolymer (PPH-2), and the third propylene homopolymer (PPH-3) differ from each other in their melt flow rates MFR2 (230° C, 2.16 kg of load).

[0077] In this embodiment, it is observed that the polymeric composition (PC) does not comprise any other polymer in an amount that exceeds 5.0% by weight, more preferably, that exceeds 3.0% by weight, even more preferably, which exceeds 1.0% by weight, even more preferably, which exceeds 0.8% by weight, based on the total weight of the polymeric composition (PC), in addition to the first propylene homopolymer (PPH-1), of the second propylene homopolymer (PPH-2), third propylene homopolymer (PPH-3) and polar modified polypropylene (PMP). In particular, it is noted that the polymeric composition (PC) does not comprise any other polymer other than the first propylene homopolymer (PPH-1), the second propylene homopolymer (PPH-2), the third propylene homopolymer (PPH-3 ) and polar modified polypropylene (PMP). Petition 870200029206, dated 03/04/2020, p. 31/85

[0078] It is observed that the propylene homopolymer (HPP-1) and the propylene homopolymer (HPP-2) included in the polymeric composition (PC) jointly satisfy inequality (Ia), preferably inequality (Ib), with more preference, inequality (Ic), even more preference, inequality (Id) [MFR (HPP-2)] / [MFR (HPP-1)] > 1.1 (Ia) 190 > [MFR (HPP-2) ] / [MFR (HPP-1)] > 1.1 (Ib) 50 > [MFR (HPP-2)] / [MFR (HPP-1)] > 1.5 (Ic) 10 > [MFR (HPP- 2)] / [MFR (HPP-1)] > 3.0 (Id) where [MFR (HPP-1)] is the melt flow rate MFR2 (230 °C, 2.16 kg) measured accordingly with ISO 1133 of propylene homopolymer (HPP-1) and [MFR (HPP-2)] is the melt flow rate MFR2 (230 °C, 2.16 kg) measured according to ISO 1133 of propylene homopolymer ( HPP-2).

[0079] It is observed that the propylene homopolymer (HPP-2) and the propylene homopolymer (HPP-3) included in the polymeric composition (PC) jointly satisfy inequality (IIa), preferably inequality (IIb), with more preferably, inequality (IIe), even more preferably, inequality (IId) [MFR (HPP-3)] / [MFR (HPP-2)] >1.1 (IIa) 25 > [MFR (HPP-3) ] / [MFR (HPP-2)] >1.0 (IIb) 20 > [MFR (HPP-3)] / [MFR (HPP-2)] > 2.0 (IIe) 15 > [MFR (HPP- 3)] / [MFR (HPP-2)] > 5.0 (IId) where melting MFR2 (230 °C, 2.16 kg) measured according to ISO 1133 of propylene homopolymer (HPP-3).

[0080] It is observed that the propylene homopolymer (HPP-1) and the propylene homopolymer (HPP-3) included in the polymeric composition (PC) jointly satisfy inequality (IIIa), preferably inequality (IIIb), with more preferably, inequality (IIIc), even more preferably, inequality (IIId) [MFR (HPP-3)] / [MFR (HPP-1)] > 4.0 (Illa) 800 > [MFR (HPP-3) ] / [MFR (HPP-1)] > 4.0 (Illb) 150 > [MFR (HPP-3)] / [MFR (HPP-1)] > 10 (IIIc) 60 > [MFR (HPP-3) ] / [MFR (HPP-1)] > 20 (IIId) where [MFR (HPP-1)] is the MFR2 melt flow rate (230 °C, 2.16 kg) measured according to ISO 1133 of the propylene homopolymer (HPP-1) and [MFR (HPP-3)] is the melt flow rate MFR2 (230 °C, 2.16 kg) measured according to ISO 1133 of propylene homopolymer (HPP-3) .

[0081] In one embodiment, polypropylene (PP) preferably comprises: (a) a first propylene homopolymer (PPH-1) and/or a second propylene homopolymer (PPH-2) and/or a third propylene homopolymer (PPH-3); and (b) a random ethylene copolymer (RPE); wherein the first propylene homopolymer (PPH-1), the second propylene homopolymer (PPH-2), and the third propylene homopolymer (PPH-3) differ from each other in their melt flow rates MFR2 (230 °C , 2.16 kg of load). Petition 870200029206, dated 03/04/2020, p. 33/85

[0082] In this embodiment, it is observed that the polymeric composition (PC) does not comprise any other polymer in an amount that exceeds 5.0% by weight, more preferably, that exceeds 3.0% by weight, even more preferably, which exceeds 1.0% by weight, even more preferably, which exceeds 0.8% by weight, based on the total weight of the polymeric composition (PC), in addition to (a) the first propylene homopolymer (PPH-1 ) and/or the second propylene homopolymer (PPH-2) and/or the third propylene homopolymer (PPH-3); (b) random ethylene copolymer (RPE); and (c) polar modified polypropylene (PMP).

[0083] In particular, it is noted that the polymeric composition (PC) does not comprise any other polymer than: (a) the first propylene homopolymer (PPH-1) and/or the second propylene homopolymer (PPH-2) and /or the third propylene homopolymer (PPH-3); (b) random ethylene copolymer (RPE); and (c) polar modified polypropylene (PMP).

[0084] In one embodiment, polypropylene (PP) preferably comprises a first propylene homopolymer (PPH-1), a second propylene homopolymer (PPH-2), a third propylene homopolymer (PPH-3 ), and a random ethylene copolymer (RPE), in which the first propylene homopolymer (PPH-1), the second propylene homopolymer (PPH-2), and the third propylene homopolymer (PPH-3) differ from each other at their MFR2 melt flow rates (230°C, 2.16kg load).

[0085] In this embodiment, it is observed that the polymeric composition (PC) does not comprise any other polymer in an amount that exceeds 5.0% by weight, more preferably, that exceeds 3.0% by weight, even more preferably , which exceeds 1.0% by weight, even more preferably, which exceeds 0.8% by weight, based on the total weight of the polymeric composition (PC), in addition to the first propylene homopolymer (PPH-1), the second propylene homopolymer (PPH-2), third propylene homopolymer (PPH-3), random ethylene copolymer (RPE) and polar modified polypropylene (PMP).

[0086] In particular, it is noted that the polymeric composition (PC) does not comprise any other polymer other than the first propylene homopolymer (PPH-1), the second propylene homopolymer (PPH-2), the third propylene homopolymer ( PPH-3), random ethylene copolymer (RPE) and polar modified polypropylene (PMP).

[0087] In one embodiment, polypropylene (PP) preferably comprises: (a) a first propylene homopolymer (PPH-1) and/or a second propylene homopolymer (PPH-2) and/or a third propylene homopolymer (PPH-3); and (b) a heterophasic propylene copolymer (HECO); wherein the first propylene homopolymer (PPH-1), the second propylene homopolymer (PPH-2), and the third propylene homopolymer (PPH-3) differ from each other in their melt flow rates MFR2 (230 °C , 2.16 kg of load).

[0088] In this embodiment, it is observed that the polymeric composition (PC) does not comprise any other polymer in an amount that exceeds 5.0% by weight, more preferably, that exceeds 3.0% by weight, even more preferably , which exceeds 1.0% by weight, even more preferably, which exceeds 0.8% by weight, based on the total weight of the polymeric composition (PC), in addition to (a) the first propylene homopolymer (PPH-1) and/or the second propylene homopolymer (PPH-2) and/or the third propylene homopolymer (PPH-3); (b) heterophasic propylene copolymer (HECO); and (c) polar modified polypropylene (PMP).

[0089] In particular, it is noted that the polymeric composition (PC) does not comprise any other polymer than: (a) the first propylene homopolymer (PPH-1) and/or the second propylene homopolymer (PPH-2) and /or the third propylene homopolymer (PPH-3); (b) heterophasic propylene copolymer (HECO); and (c) polar modified polypropylene (PMP).

[0090] In one embodiment, polypropylene (PP) preferably comprises a first propylene homopolymer (PPH-1), a second propylene homopolymer (PPH-2), a third propylene homopolymer (PPH-3) and a heterophasic propylene copolymer (HECO), wherein the first propylene homopolymer (PPH-1), the second propylene homopolymer (PPH-2) and the third propylene homopolymer (PPH-3) differ from each other in their MFR2 melt flow rates (230 °C, 2.16 kg load).

[0091] In this modality, it is observed that the polymeric composition (PC) does not include any other polymer in Petition 870200029206, of 03/04/2020, page. 36/85 an amount exceeding 5.0% by weight, more preferably exceeding 3.0% by weight, even more preferably exceeding 1.0% by weight, even more preferably exceeding 0. 8% by weight, based on the total weight of the polymeric composition (PC), in addition to the first propylene homopolymer (PPH-1), the second propylene homopolymer (PPH-2), the third propylene homopolymer (PPH-3) , heterophasic propylene copolymer (HECO) and polar modified polypropylene (PMP).

[0092] In particular, it is noted that the polymeric composition (PC) does not comprise any other polymer other than the first propylene homopolymer (PPH-1), the second propylene homopolymer (PPH-2), the third propylene homopolymer ( PPH-3), heterophasic propylene copolymer (HECO) and polar modified polypropylene (PMP).

[0093] The polymeric composition (C) can be obtained by melt mixing. This process may include the steps of adding (a) polypropylene (PP); (b) polar modified polypropylene (PMP); and (c) carbon fibers (CF); to an extruder and extrude it obtaining said polymeric composition (PC).

[0094] The polymeric composition (PC) can be formed and pelletized using any of a variety of compounding and blending machines and methods that are well known and commonly used in the resin compounding technique. However, it is preferred to use a compounding and blending method that does not affect the dimensions of carbon fiber or the dimensions of fibers other than carbon fibers.

[0095] To blend the individual components of the present composition, a conventional compounding or blending apparatus, for example, a Banbury mixer, a 2-cylinder rubber mill, Buss kneader or a twin-screw extruder can be used. The polymer materials recovered from the extruder/mixer are typically in pellet format. These pellets are then preferably further processed, for example, by injection molding to generate articles and products of the inventive composition. Propylene Homopolymer (PPH-1)

[0096] The propylene homopolymer (PPH-1) consists substantially, that is, of more than 99.7% by weight, even more preferably, of at least 99.8% by weight, of propylene units, based in the weight of propylene homopolymer (PPH-1). In a preferred embodiment, only propylene units are detectable in the propylene homopolymer (PPH-1).

[0097] The propylene homopolymer (PPH-1) may have an MFR2 (230 °C) melt flow rate measured in accordance with ISO 1133 of at least 1.0 g/10 min, preferably at least 5. 0 g/10 min, more preferably at least 10 g/10 min, even more preferably at least 15 g/10 min, as in the range of 1.0 to 45 g/10 min, preferably in the range from 5.0 to 40 g/10 min, more preferably in the range of 10 to 30 g/10 min, and most preferably in the range of 15 to 25 g/10 min.

[0098] It is observed that the propylene homopolymer (PPH-1) has a low amount of xylene cold soluble fraction (XCS). The propylene homopolymer (PPH-1) may have an amount of xylene cold soluble fraction (XCS) of no more than 4.0% by weight, preferably no more than 3.0% by weight, more preferably , not more than 2.5% by weight, such as in the range of 0.1 to 4.0% by weight, preferably in the range of 0.1 to 3.0% by weight, more preferably in the range of 0.1 to 2.5% by weight, based on the weight of propylene homopolymer (PPH-1).

[0099] The propylene homopolymer (PPH-1) may have a heat deformation temperature (HDT) measured in accordance with ISO 75-2 of at least 90 °C, preferably at least 100 °C, more preferably, at least 115 °C, such as in the range of 90 to 160 °C, preferably, in the range of 100 to 150 °C, more preferably, 115 to 130 °C.

[0100] Propylene homopolymer (PPH-1) may have a Charpy Impact Resistance measured in accordance with ISO 179-leU:2000 at 23 °C of at least 1.0 kJ/m2, preferably at least 2 .0 kJ/m2, such as in the range of 1.0 to 10 kJ/m2, preferably in the range of 2.0 to 5.0 kJ/m2.

[0101] The propylene homopolymer (PPH-1) may have a flexural modulus measured in accordance with ISO 178 of at least 500 MPa, preferably at least 1500 MPa, as in the range of 500 to 3500 MPa, preferably, in the range of 1500 to 2500 MPa.

[0102] Propylene homopolymer (PPH-1) can polymerize nucleation. The alpha-nucleating agent content of the propylene homopolymer (PPH-1) is preferably up to 5.0% by weight. In a preferred embodiment, the propylene homopolymer (PPH-1) contains no more than 3000 ppm, more preferably, 1 to 2000 ppm of alpha-nucleating agent.

[0103] More details about alpha-nucleating agents are provided in the "Polymeric Composition (PC)" section. Propylene homopolymer (PPH-1) is known in the art and is commercially available. A suitable example is HF955MO from Borealis AG.

Propylene Homopolymer (PPH-2)

[0104] The propylene homopolymer (PPH-2) consists substantially, that is, of more than 99.7% by weight, even more preferably, of at least 99.8% by weight, of propylene units, based in the weight of propylene homopolymer (PPH-2). In a preferred embodiment, only propylene units are detectable in the propylene homopolymer (PPH-2).

[0105] The propylene homopolymer (PPH-2) may have an MFR2 melt flow rate (230 °C) measured in accordance with ISO 1133 at least 50 g/10 min, preferably at least 60 g/10 min , more preferably at least 65 g/10 min, even more preferably at least 70 g/10 min, such as in the range of 50 to 190 g/10 min, preferably in the range of 60 to 150 g/10 min, more preferably in the range of 65 to 100 g/10 min, even more preferably in the range of 70 to 80 g/10 min.

[0106] It is observed that the propylene homopolymer (PPH-2) has a low amount of xylene cold soluble fraction (XCS). The propylene homopolymer (PPH-2) may have an amount of xylene cold soluble fraction (XCS) of no more than 4.0% by weight, preferably no more than 3.5% by weight, as in the range from 0.1 to 4.0% by weight, preferably in the range of 0.1 to 3.5% by weight, based on the weight of the propylene homopolymer (PPH-2).

[0107] The propylene homopolymer (PPH-2) may have a heat deformation temperature (HDT) measured in accordance with ISO 75-2 of at least 50 °C, preferably at least 60 °C, more preferably at least 75°C, such as in the range of 50 to 120°C, preferably in the range of 60 to 100°C, more preferably 75 to 90°C.

[0108] Propylene homopolymer (PPH-2) may have a Charpy Notch Impact Resistance (NIS) measured in accordance with ISO 179-1eA at 23 °C of at least 0.5 kJ/m2, preferably, at least 0.7 kJ/m2, such as in the range of 0.5 to 1.5 kJ/m2, preferably in the range of 0.7 to 1.3 kJ/m2.

[0109] The propylene homopolymer (PPH-2) may have a flexural modulus measured in accordance with ISO 178 of at least 500 MPa, preferably at least 1000 MPa, as in the range of 500 to 2500 MPa, preferably, in the range of 1000 to 2000 MPa.

[0110] In the case where the propylene homopolymer (PPH-2) comprises an alpha-nucleating agent, it is observed that the propylene homopolymer (PPH-2) can comprise the alpha-nucleating agent in an amount of up to 5.0% by weight, based on the weight of the propylene homopolymer (PPH-2), preferably up to 3000 ppm, as in the range of 1 to 2000 ppm. However, in a preferred embodiment, the propylene homopolymer (PPH-2) does not comprise any nucleating agent, that is, the propylene homopolymer (PPH-2) is not nucleated.

[0111] More details about alpha-nucleating agents are provided in the "Polymeric Composition (PC)" section.

[0112] Propylene homopolymer (PPH-2) is known in the art and is commercially available. A suitable example is HJ120UB from Borealis AG.

Propylene Homopolymer (PPH-3)

[0113] The propylene homopolymer (PPH-3) consists substantially, that is, of more than 99.7% by weight, even more preferably, of at least 99.8% by weight, of propylene units, based in the weight of propylene homopolymer (PPH-3). In a preferred embodiment, only propylene units are detectable in the propylene homopolymer (PPH-3).

[0114] The propylene homopolymer (PPH-3) may have an MFR2 melt flow rate (230 °C) measured in accordance with ISO 1133 at least 200 g/10 min, preferably at least 300 g/10 min , more preferably at least 400 g/10 min, even more preferably at least 420 g/10 min, such as in the range of 200 to 800 g/10 min, preferably in the range of 300 to 600 g/10 min, more preferably in the range of 400 to 500 g/10 min, even more preferably in the range of 420 to 480 g/10 min.

[0115] The propylene homopolymer (PPH-3) can have a xylene cold soluble fraction (XCS) content of no more than 10% by weight, preferably no more than 7.0% by weight, even with more preferably not more than 4.5% by weight, such as in the range of 0.1 to 10% by weight, preferably in the range of 0.5 to 7.0% by weight, more preferably in the range of 2.0 to 4.5% by weight, based on the weight of the weight of the propylene homopolymer (PPH-3).

[0116] The propylene homopolymer (PPH-3) may have a melting temperature Tm of at least 150 °C, preferably at least 158 °C, as in the range of 150 to 180 °C, preferably in the range from 158 to 170 °C, more preferably in the range of 161 to 165 °C.

[0117] The propylene homopolymer (PPH-3) may comprise a nucleating agent which is preferably a polymeric nucleating agent, more preferably an alpha-nucleating agent, for example, an alpha-nucleating agent polymeric.

[0118] The alpha-nucleating agent content of the propylene homopolymer (PPH-3) is preferably up to 5.0% by weight. In a preferred embodiment, the propylene homopolymer (PPH-3) contains no more than 3000 ppm, more preferably, 1 to 2000 ppm of alpha-nucleating agent.

[0119] More details about alpha-nucleating agents are provided in the "Polymeric Composition (PC)" section.

[0120] Propylene homopolymer (PPH-3) is known in the art and is commercially available. A suitable example is HL504FB from Borealis AG.

Random Ethylene Copolymer (RPE)

[0121] The polypropylene (PP) composition may comprise a random ethylene copolymer (RPE).

[0122] The random ethylene copolymer (RPE) is, preferably, an elastomeric copolymer that comprises, preferably consists of, ethylene-derivable units and units derivable from at least one C3 to C10 alpha-olefin, preferably at least at least one C3 to C8 alpha-olefin, more preferably at least one C4 to C8 alpha-olefin, such as at least one C3 to C8 alpha-olefin, preferably at least one C4 to C8 alpha-olefin; more preferably, units derivable from ethylene and units derivable from at least one alpha-olefin selected from the group consisting of 1-butene, 1-pentene, 1-hexene, 1-heptene and 1-octene, preferably selected from of 1-butene and 1-octene, more preferably, of 1-octene.

[0123] Consequently, the random ethylene copolymer (RPE) comprises at least units derivable from ethylene and units derivable from an additional alpha-olefin as defined in the previous paragraph. However, it is particularly preferred that the random ethylene copolymer (RPE) comprises units derivable only from ethylene and units derivable from an additional alpha-olefin such as 1-butene, 1-pentene, 1-hexene, 1-heptene and 1-octene. It is especially preferred that the random ethylene copolymer (RPE) comprises only units derivable from ethylene and units selected from 1-butene, 1-hexene and 1-octene. In one embodiment, the random ethylene copolymer (RPE) comprises units derivable only from ethylene and units derivable from 1-octene.

[0124] Random ethylene copolymer (RPE) can be comprised of polypropylene (PP) in the form of elastomeric inclusions (finely) dispersed in a semi-crystalline or crystalline matrix phase, such as a matrix phase comprising propylene homopolymer (PPH -1), propylene homopolymer (PPH-2) and propylene homopolymer (PPH-3). The random ethylene copolymer (RPE) can form inclusions (finely dispersed) within other elastomeric compounds, such as an additional random ethylene copolymer or the elastomeric phase of a heterophasic propylene copolymer. However, it is preferred that the random ethylene copolymer (RPE) is the only elastomeric compound in the polymeric composition (PC).

[0125] The random ethylene copolymer (RPE) may have an MFR2 melt flow rate (190 °C, 2.16 kg) measured in accordance with ISO 1133 of no more than 100 g/10 min, preferably of no more than 50 g/10 min, more preferably no more than 40 g/10 min, even more preferably no more than 35 g/10 min, as in the range of 0.2 to 100 g/10 min, preferably in the range of 0.5 to 50 g/10 min, more preferably in the range of 0.5 to 40 g/10 min, even more preferably in the range of 0.5 to 35 g/10 min 10 min, even more preferably, in the range of 0.5 to 30 g/10 min.

[0126] In one embodiment, the random ethylene copolymer (RPE) has an MFR2 melt flow rate (190 °C, 2.16 kg) measured in accordance with ISO 1133 in the range of 5.0 to 80 g/10 min, preferably in the range of 10 to 50 g/10 min, more preferably in the range of 20 to 40 g/10 min, even more preferably in the range of 25 to 35 g/10 min.

[0127] In one embodiment, the random ethylene copolymer (RPE) has a melt flow rate MFR2 (190 °C, 2.16 kg) measured in accordance with ISO 1133 in the range of 0.1 to 10 g/10 min, preferably in the range of 0.3 to 5.0 g/10 min, more preferably in the range of 0.5 to 2.0 g/10 min, even more preferably in the range of 0.7 at 1.3 g/10 min.

[0128] The random ethylene copolymer (RPE) may have a density measured in accordance with ISO 1183-187 of no more than 910 kg/cm3, preferably no more than 885 kg/cm3, as in the range of 854 to 910 kg/cm3, preferably in the range of 854 to 885 kg/cm3.

[0129] The random ethylene copolymer (RPE) may have an ethylene content of at least 80 mol%, preferably at least 92 mol%, as in the range of 80 to 98 mol%, preferably, in the range of 82 to 92 mol%.

[0130] In other words, the random ethylene copolymer (RPE) may comprise at least one C3 to C10 alpha-olefin, preferably, at least one C3 to C8 alpha-olefin, more preferably, at least one C4 to C8 alpha-olefin, in 1-butene, 1-hexene and 1-octene, preferably 1-octene, in an amount of up to 20 mol%, preferably up to 18 mol%, as in range from 2.0 to 20 mol%, preferably in the range from 8 to 18 mol%.

[0131] Random ethylene copolymer (RPE) is known in the art and is commercially available. Suitable examples are Queo8230 and Queo8201 from Borealis AG.

Heterophase Propylene Copolymer (HECO)

[0132] The polypropylene (PP) composition may comprise a heterophasic propylene copolymer (HECO).

[0133] As indicated above, a heterophasic propylene copolymer comprises as polymeric components a polypropylene matrix and an elastomeric copolymer.

[0134] The heterophasic propylene copolymer (HECO) preferably comprises (a) a polypropylene matrix (M) and (b) an elastomeric copolymer (E) comprising units derived from - propylene and - ethylene and/or C4 a C20 alpha-olefins, most preferably ethylene and/or C4 to C10 alpha-olefins, and most preferably ethylene, C4, C6 and/or C8 alpha-olefins, for example ethylene and, optionally, units thereof of a conjugated diene.

[0135] The polypropylene matrix (M) is preferably a random propylene copolymer or a propylene homopolymer, the latter being especially preferred.

[0136] In the case where the polypropylene matrix (M) is a propylene homopolymer, it is noted that the comonomer content of the polypropylene matrix (M) should be no more than 1.0% by weight, preferably, not more than 0.8% by weight, more preferably not more than 0.5% by weight, such as not more than 0.2% by weight, based on the weight of the polypropylene matrix (M).

[0137] In the case where the polypropylene matrix (M) is a random propylene copolymer, it is observed that the random propylene copolymer comprises monomers copolymerizable with propylene, for example, comonomers such as ethylene and/or C4 to C20 alpha- olefins, in particular, ethylene and/or C4 to C10 alpha-olefins, for example, ethylene, C4, C6 and/or C8 alpha-olefins. Preferably, the random propylene copolymer comprises, especially consists of monomers copolymerizable with propylene from the group consisting of ethylene, 1-butene and 1-hexene. More specifically, the random propylene copolymer comprises - in addition to propylene - units derivable from ethylene and/or 1-butene. In a preferred embodiment, the random propylene copolymer comprises units derivable from ethylene and propylene only. Additionally, it is noted that the random propylene copolymer preferably has a comonomer content in the range of 0.3 to 1.0% by weight, more preferably in the range of more than 0.3 to 0.8% by weight. % by weight, even more preferably, in the range of 0.3 to 0.7 % by weight, based on the weight of the random propylene copolymer.

[0138] The polypropylene matrix (M) can be isotactic. Consequently, it is observed that the polypropylene matrix (M) has a very high pentad concentration, that is, greater than 80%, preferably greater than 85%, more preferably greater than 90%, even more preferably, greater than 92%, even more preferably, greater than 93%, as greater than 95%.

[0139] Additionally, it is observed that the polypropylene matrix (M) of the heterophasic propylene copolymer (HECO) has a higher melt flow rate. As previously stated, the MFR2 melt flow rate (230 °C, 2.16 kg) measured according to ISO1133 of the polypropylene matrix (M) equals the MFR2 melt flow rate of the xylene cold insoluble fraction ( XCI) of heterophasic propylene copolymer (HECO). Therefore, it is preferred that the xylene cold insoluble fraction (XCI) of the heterophasic propylene copolymer (HECO) has a melt flow rate MFR2 (230 °C, 2.16 kg) measured according to ISO 1133 in the range from 50 to 200 g/10 min, more preferably in the range of 80 to 150 g/10 min, even more preferably in the range of 100 to 130 g/10 min.

[0140] Heterophasic polypropylene (HECO) may have an MFR2 (230 °C, 2.16 kg) measured in accordance with ISO 1133 of no more than 60 g/10 min, preferably no more than 40 g/10 min , more preferably not more than 30 g/10 min, such as in the range of 5.0 to 60 g/10 min, more preferably in the range of 10 to 40 g/10 min, more preferably in the range of 20 at 30 g/10 min.

[0141] Heterophasic polypropylene (HECO) may have a total comonomer content of no more than 35 mol%, preferably no more than 30 mol%, more preferably no more than 22 mol%, as in range of 5.0 to 35 mol%, preferably in the range of 10 to 30 mol%, more preferably in the range of 15 to 22 mol%.

[0142] Heterophasic polypropylene (HECO) may have an amount of xylene cold soluble fraction (XCS) of no more than 60% by weight, preferably no more than 45% by weight, more preferably no more than 35% by weight, as in the range of 10 to 60% by weight, preferably in the range of 20 to 45% by weight, more preferably in the range of 25 to 35% by weight, based on the total weight of the polypropylene heterophasic (HECO).

[0143] Heterophasic polypropylene (HECO) may have an intrinsic viscosity (IV) of the xylene cold soluble fraction (XCS) of no more than 4.5 dl/g, preferably no more than 3.5 dl/g , such as in the range of 2.0 to 4.5 dl/g, preferably in the range of 2.7 to 3.5 dl/g.

[0144] Heterophasic polypropylene (HECO) may have a xylene cold soluble fraction (XCS) comonomer content of no more than 65 mol %, preferably no more than 60 mol %, more preferably no more than 55 mol%, such as in the range of 30 to 65 mol%, preferably in the range of 40 to 60 mol%, more preferably in the range of 45 to 55 mol%.

[0145] Typically, the xylene cold insoluble fraction (XCI) of the heterophasic propylene copolymer (HECO) represents the crystalline or semicrystalline part of the heterophasic propylene copolymer (HECO), that is, the matrix (M), whereas the xylene cold soluble fraction (XCS) represents an elastomeric part of the heterophasic propylene copolymer (HECO), that is, the elastomeric copolymer (E).

[0146] The matrix content (M), that is, the content of xylene cold insoluble (XCI), in the heterophasic propylene copolymer (HECO) is preferably in the range of 60 to 90% by weight, with more preferably in the range of 65 to 80% by weight, based on the weight of the heterophasic propylene copolymer (HECO).

[0147] The content of elastomeric copolymer (E), that is, the content of cold soluble xylene (XCS) in the heterophasic propylene copolymer (HECO), is preferably in the range of 10 to 40% by weight, with more preferably 20 to 35% by weight, based on the weight of the heterophasic propylene copolymer (HECO).

[0148] The heterophasic propylene copolymer (HECO) as well as its individual components (matrix and elastomeric copolymer) can be produced by mixing different types of polymer. However, it is preferred that the heterophasic propylene copolymer (HECO) as well as its individual components (matrix and elastomeric copolymer) are produced in a sequential step process, using reactors in series configuration and operating under different reaction conditions.

[0149] Heterophasic propylene copolymer (HECO) is known in the art and is commercially available. A suitable example is EG066AI from Borealis AG.

Polar Modified Polypropylene (PMP)

[0150] In order to achieve an easier and more uniform dispersion of carbon fibers (CF) in the polymer components; which act as a matrix for carbon fibers (CF) in the polymeric composition (PC); a polar modified polypropylene (PMP) is applied as a coupling agent.

[0151] Polar modified polypropylene (PMP) is preferably a polypropylene that contains polar groups.

[0152] In the following, polypropylene will be defined more precisely, which is subsequently modified to a polar modified polypropylene (PMP) as explained in detail below.

[0153] Polypropylene is preferably a propylene homopolymer or a random propylene copolymer, such as a copolymer of (i) propylene and (ii) ethylene and/or C4 to C12 α-olefins, preferably of (i ) propylene and (ii) an α-olefin selected from the group consisting of ethylene, 1-butene, 1-hexene, 1-octene, and mixtures thereof, preferably ethylene.

[0154] In one embodiment, the modified polypropylene Petition 870200029206, of 03/04/2020, p. 51/85 (PMP) is a modified random propylene copolymer, wherein said random propylene copolymer comprises ethylene as the only comonomer unit.

[0155] The polypropylene from which polar modified polypropylene (PMP) is prepared can also be a propylene homopolymer. However, it is preferred that the polypropylene from which polar modified polypropylene (PMP) is prepared is a random propylene copolymer.

[0156] In one embodiment, the polypropylene from which polar modified polypropylene (PMP) is prepared is a random propylene copolymer comprising only ethylene-derived comonomer units.

[0157] Regarding the definition of the term "random propylene copolymer", reference is made to the information provided above that discusses polypropylene (PP).

[0158] Preferably, the propylene derivatizable units constitute the main part of the random propylene copolymer, that is, at least 90.0% by weight, more preferably, in the range of 92.0 to 99.5% by weight , even more preferably, from 92.5 to 98.0% by weight, even more preferably, from 93.0 to 96.0% by weight, based on the total weight of the random propylene copolymer. Consequently, the amount of ethylene-derived and/or C4 to C12 α-olefin units, preferably ethylene-derived, in the random propylene copolymer is at most 10.0% by weight, preferably in the range of 0.5 to 8.0% by weight, more preferably from 2.0 to 7.5% by weight, even more preferably from 4.0 to 7.0% by weight, based on the total weight of the propylene copolymer random.

[0159] It should be noted, in particular, that the random propylene copolymer only comprises units derivable from propylene and ethylene. The comonomer amounts given in this paragraph preferably belong to the random propylene copolymer that is not modified.

[0160] It is observed that the random propylene copolymer, that is, the unmodified random propylene copolymer, has a melting temperature Tm in the range of 125 to 140 ° C, more preferably, in the range of 128 to 138 ° C even more preferably, in the range of 131 to 136 ° C. The melting temperature given in this paragraph is the melting temperature of the unmodified random propylene copolymer.

[0161] It is noted that the random propylene copolymer, that is, the unmodified random propylene copolymer, has a melt flow rate MFR2 (230 ° C) measured according to ISO 1133 in the range of 1 to 30 g/10 min, preferably in the range of 1 to 20 g/10 min, more preferably in the range of 1 to 10 g/10 min, and most preferably in the range of 2 to 6 g/10 min .

[0162] It is observed that polar modified polypropylene (PMP) comprises groups derived from polar groups. In this context, preference is given to polar modified polypropylene (PMP) comprising groups derived from polar compounds, in particular, selected from the group consisting of acid anhydrides, carboxylic acids, carboxylic acid derivatives, primary and secondary amines, compounds of hydroxyl, oxazoline and epoxides, and also ionic compounds.

[0163] Specific examples of said polar groups are unsaturated cyclic anhydrides and their aliphatic diesters, and diacid derivatives. In particular, the element may use maleic anhydride and compounds selected from C1 to C10 linear and branched dialkyl maleates, C1 to C10 linear and branched dialkyl fumarates, itaconic anhydrides, C1 to C10 linear and branched dialkyl itaconic acid esters , maleic acid, fumaric acid, itaconic acid and mixtures thereof.

[0164] In terms of structure, polar modified polypropylene (PMP) is preferably selected from graft or block copolymers, preferably from the polypropylene defined above, such as the random propylene copolymer defined above.

[0165] Preferably, the polar modified polypropylene (PMP), that is, the coupling agent, is a polypropylene, such as the random propylene copolymer as defined above in the section “polar modified propylene (PMP) as a coupling agent”. , grafted with such a polar group.

[0166] Particular preference is given to the use of a polypropylene, such as the random propylene copolymer as defined above in the section "Polar Modified Propylene (PMP)" grafted with maleic anhydride such as polar modified polypropylene (PMP), that is, the coupling agent.

[0167] In one embodiment, the modified polypropylene random propylene grafted with maleic anhydride, more preferably, wherein the ethylene content based on the total amount of the ethylene and random propylene copolymer is in the range of 2.0 to 7.5 % by weight, more preferably in the range of 4.0 to 7.0 % by weight.

[0168] In order to achieve the desired dispersion of the carbon fibers (CF) in the polymeric components ensuring that the polymeric composition (C) provides well-balanced mechanical properties, in particular, a high impact resistance in combination with a high elongation at rupture at low density, it is observed that polar modified polypropylene (PMP) comprises a number of groups that derive from polar groups that are larger than those typically used in polar modified polypropylenes considered for polypropylenes.

[0169] Polar modified polypropylene (PMP) may comprise groups that derive from polar groups in an amount in the range of 0.5 to 5.0% by weight, preferably in the range of 1.0 to 4.0% by weight. weight, more preferably in the range of 1.5 to 3.0% by weight, even more preferably in the range of 1.7 to 2.3% by weight, based on the total weight of the polar modified polypropylene (PMP ).

[0170] Polar modified polypropylene (PMP) may have an MVI melt flow volume rate (170 °C; 1.2 kg) measured in accordance with ISO 1133 in the range of 20 to 150 cm3/10 min, preferably , in the range of 40 to 100 cm3/10 min.

[0171] In one embodiment, polar modified polypropylene (PMP) is a maleic anhydride-grafted random ethylene and propylene copolymer with an ethylene content based on the total amount of random ethylene and propylene copolymer in the range of 2.0 to 7. .5 wt %, which has groups that derive from polar groups in an amount in the range of 0.5 to 5.0 wt % and a melt flow volume rate MVI (170 °C; 1.2 kg) measured according to ISO 1133 in the range of 20 to 150 cm3/10 min.

[0172] In one embodiment, polar modified polypropylene (PMP) is a random ethylene propylene copolymer grafted with maleic anhydride with an ethylene content based on the total amount of the random ethylene propylene copolymer that is in the range of 2.0 to 3.0 wt %, which has groups that derive from polar groups in an amount in the range of 1.5 to 3.0 wt % and a melt flow volume rate MVI (170 °C; 1.2 kg) measured according to ISO 1133 in the range of 40 to 100 cm3/10 min.

[0173] In one embodiment, polar modified polypropylene (PMP) is a maleic anhydride-grafted random ethylene and propylene copolymer with an ethylene content based on the total amount of the random ethylene and propylene copolymer that is in the range of 2. 0 to 2.8 wt %, which has groups that derive from polar groups in an amount in the range of 1.7 to 2.3 wt % and a melt flow volume rate MVI (170 °C; 1. 2 kg) measured according to ISO 1133 in the range of 40 to 100 cm3/10 min.

[0174] Additionally or alternatively, it is observed that polar modified polypropylene (PMP) preferably has a melting temperature Tm in the range of 120 to 150 °C, more preferably in the range of 125 to 145 °C and, most preferably, in the range of 130 to 140 °C.

[0175] Polar modified polypropylene (PMP) can be produced in a simple manner by a two-step grafting process comprising a solid stage as a first step and a melt stage as a second step. Such process steps are well known in the art.

[0176] Polar modified polypropylene (PMP) is known in the art and is commercially available. A suitable example is SCONA TSPP 10213 GB from BYK.

[0177] The polymeric composition (PC) may comprise polar modified polypropylene (PMP) in an amount in the range of 2.5 to 10 parts by weight, preferably in the range of 3.0 to 7.0 parts by weight, more preferably, in the range of 3.0 to 6.0 parts by weight, based on the total parts by weight of polypropylene (PP), polar modified polypropylene (PMP) and carbon fibers (CF).

[0178] In one embodiment, the polymeric composition (PC) comprises polar modified polypropylene (PMP) in an amount in the range of 2.5 to 10 parts by weight, based on the total parts by weight of polypropylene (PP), polar modified polypropylene (PMP) and carbon fibers (CF).

[0179] In one embodiment, the polymeric composition (PC) comprises polar modified polypropylene (PMP) in an amount in the range of 3.0 to 6.0 parts by weight, based on the total parts by weight of polypropylene (PP ), polar modified polypropylene (PMP) and carbon fibers (CF).

[0180] The polymeric composition (PC) may comprise polar modified polypropylene (PMP) in an amount of at least 2.5% by weight, preferably at least 3.0% by weight, such as an amount in the range of 2 5 to 10% by weight, preferably in the range of 3.0 to 7.0% by weight, based on the total weight of the polymeric composition (PC).

[0181] In one embodiment, the polymeric composition (PC) comprises polar modified polypropylene (PMP) in an amount ranging from 2.5 to 10% by weight, based on the total weight of the polymeric composition (PC).

[0182] In one embodiment, the polymeric composition (PC) comprises polar modified polypropylene (PMP) in an amount in the range of 3.0 to 6.0 parts by weight, based on the total weight of the polymeric composition (PC).

[0183] Preferably, polar modified polypropylene (PMP) is the only polar modified polypropylene present in the polymeric composition (PC). In one embodiment, polar modified polypropylene (PMP) is the only polar modified polypropylene present in the polymeric composition (PC).

Carbon Fibers (CF)

[0184] It should be noted that the polypropylene composition (C) must have well-balanced mechanical properties, in particular, a high impact resistance in combination with a high elongation at break. In order to achieve these properties, the inclusion of carbon fibers (CF) is an essential requirement.

[0185] Carbon fibers (CF) may have an average diameter in the range of 2 to 30 μm, preferably in the range of 3 to 25 μm, more preferably in the range of 5 to 20 μm.

[0186] Carbon fibers (CF) can have a density in the range of 1.0 to 2.5 g/cm3, preferably in the range of 1.5 to 2.3 g/cm3, more preferably in the range range from 1.7 to 2.0 g/cm3.

[0187] It should be noted that carbon fibers are not considered a polymeric material. Additionally, carbon fibers (CF) are not recognized as falling within the term "additives (AD)" as defined in greater detail below.

[0188] Carbon fibers (CF) can be in the form of a non-woven cloth. The non-woven cloth preferably comprises at least 50% by weight of carbon fibers (CF), more preferably at least 65% by weight of carbon fibers, even more preferably at least 75% by weight of carbon fibers (CF) and, most preferably, at least 80% by weight, based on the total weight of the non-woven cloth.

[0189] The non-woven cloth according to the invention may comprise polymeric compounds such as sizing agents and/or sewing threads. It is noted that the sizing agents and/or sewing threads are not comprised in an amount exceeding 10% by weight, preferably 7.5% by weight, even more preferably 3% by weight, based on weight. of carbon fiber (CF). Sizing agents and/or sewing threads are considered to fall within the term "carbon fiber (CF)" and do not resemble additional polymeric compounds.

[0190] If present, the amount of sewing thread is normally in the range of 0.25 to 10% by weight, preferably in the range of 0.5 to 7.5% by weight, and most preferably in the range from 1.0 to 3.0% by weight based on the total weight of the non-woven cloth. Suitable sewing threads are, for example, polyester fibers. As indicated above, Petition 870200029206, dated 03/04/2020, p. 59/85 sewing threads are considered to be covered by the term "carbon fiber (CF)" and do not resemble additional polymeric compounds.

[0191] If present, the amount of sizing agents is typically in the range of 0.25 to 15% by weight, preferably 0.5 to 10% by weight, more preferably 1.0 to 7. 5% by weight, based on the weight of carbon fibers (CF). Suitable sizing agents are, for example, epoxy resins, polyether-modified epoxy resins, polyurethane, silane-amine grafted polypropylene. As indicated above, sizing agents are considered to fall within the term "carbon fiber (CF)" and do not resemble additional polymeric compounds.

[0192] It is noted that non-woven cloth may be a recycled material that may contain additional compounds in addition to carbon fibers, such as smaller amounts of glass fibers, depending on the first use. These additional compounds are considered to be covered by the term "carbon fiber (CF)" and do not resemble additional compounds, in particular, polymeric compounds and/or additional fiber compounds.

[0193] It should be noted that these additional compounds, such as glass fibers, are not comprised in an amount that exceeds 10% by weight, preferably 5% by weight, even more preferably 3% by weight, based on the carbon fiber weight (CF). In one embodiment, the carbon fiber (CF) does not comprise glass fibers in an amount that exceeds 5% by weight, based on the weight of the carbon fiber (CF). Petition 870200029206, dated 03/04/2020, p. 60/85

[0194] In one embodiment, the carbon fiber (CF) does not comprise glass fibers.

[0195] In the case where the carbon fibers (CF) are in the form of a non-woven cloth, the non-woven cloth is preferably in the form of a strip.

[0196] Usually, the width of the strip is no more than 300 mm. Preferably, the strip has a width of 10 to 300 mm, preferably a width of 25 to 250 mm and most preferably a width of 40 to 200 mm. Additionally or alternatively, the strip preferably has a length of at least 50 cm, more preferably at least 150 cm and most preferably at least 250 cm.

[0197] The strip may be in the form of a spool. Thus, the length is not particularly limited. However, the length is not particularly limited, i.e. the strip can be a so-called “endless strip”.

[0198] The average weight of the non-woven cloth is preferably in the range of 100 to 1000 g/m2, more preferably in the range of 150 to 800 g/m2 and most preferably in the range of 250 to 650 g/m2.

[0199] The non-woven cloth is additionally characterized by a constant weight per area. Thus, the difference in weight between two sections of the non-woven cloth having an identical area expressed in the quotient of the section having the greatest weight to the section having the smallest weight is preferably within 10%, more preferably, within 5%.

[0200] The preparation of non-woven cloth from carbon fibers (CF), for example, roving, or recycled material which can be in the form of an arranged blanket, is well known in the art. Suitable processes are, for example, needle piercing.

[0201] Preferably, the non-woven cloth is in the form of a non-woven cloth, preferably obtained by needle punching.

[0202] The polymeric composition (PC) may comprise carbon fibers (CF) in an amount of 2.5 to 35 parts by weight, preferably in an amount of 5.0 to 30 parts by weight, more preferably , in the range of 10 to 25 parts by weight, even more preferably, in the range of 17 to 23 parts by weight, based on the total parts by weight of polypropylene (PP), polar modified polypropylene (PMP) and carbon fibers (CF).

[0203] In one embodiment, the polymeric composition (PC) comprises carbon fibers (CF) in an amount in the range of 2.5 to 45 parts by weight, based on the total parts by weight of polypropylene (PP), polar modified polypropylene (PMP) and carbon fibers (CF).

[0204] In one embodiment, the polymeric composition (PC) comprises carbon fibers (CF) in an amount in the range of 17 to 23 parts by weight, based on the total parts by weight of polypropylene (PP), modified polypropylene polar (PMP) and carbon fibers (CF).

[0205] The polymeric composition (PC) may comprise carbon fibers (CF) in an amount of at least 2.5% by weight, preferably at least 5.0% by weight, more preferably at least 10 % by weight, even more preferably at least 17% by weight, as an amount in the range of 2.5 to 45% by weight, more preferably in the range of 5.0 to 30% by weight, even more preferably , in the range of 10 to 25.0% by weight, even more preferably, in the range of 17 to 23% by weight, based on the total weight of the polymeric composition (PC).

[0206] In one embodiment, the polymeric composition (PC) comprises carbon fibers (CF) in an amount ranging from 2.5 to 45% by weight, based on the total weight of the polymeric composition (PC).

[0207] In one embodiment, the polymeric composition (PC) comprises carbon fibers (CF) in an amount in the range of 17 to 23 parts by weight, based on the total weight of the polymeric composition (PC).

[0208] Preferably, carbon fibers (CF) are the only fibers present in the polymeric composition (PC). In one embodiment, the polymeric composition (PC) does not comprise fibers selected from the group consisting of glass fibers, metallic fibers, mineral fibers, ceramic fibers and mixtures thereof. In one embodiment, the polymeric composition (PC) does not comprise fibers obtained from an inorganic material.

Additives (AD)

[0209] In addition to polypropylene (PP), polar modified polypropylene (PMP) and carbon fibers (CF), polymer compositions (PC) may comprise additives (AD).

[0210] Typical additives are acid sequestrants, antioxidants, dyes, light stabilizers, plasticizers, non-stick agents, anti-scratch agents, dispersing agents, processing aids, lubricants, pigments, anti-static agents and the like.

[0211] Such additives are commercially available and are, for example, described in “Plastic Additives Handbook”, 6th edition 2009 by Hans Zweifel (pages 1141 to 1190).

[0212] As indicated above, the term "additives (AD)" does not include fibers such as carbon fibers, glass fibers, metallic fibers, mineral fibers and ceramic fibers. In other words, carbon fibers (CF) are not related to an additive.

[0213] However, the term "additives (AD)" may also include carrier materials, in particular, polymeric carrier materials (PCM).

[0214] The polymeric composition (PC) may comprise additives (AD) in an amount of up to 10% by weight, preferably in an amount in the range of 0.01 to 10% by weight, more preferably in a an amount in the range of 0.05 to 5% by weight, even more preferably, in an amount in the range of 0.1 to 2.5% by weight, based on the weight of the polymeric composition (PC).

[0215] The polymeric composition (PC) may comprise additives selected from the group of antioxidant, acid remover, anti-scratch agent, mold release agent, lubricant, UV stabilizer and mixtures thereof.

[0216] Additives (AD) can be included in the polymeric composition (PC) as a separate ingredient. Alternatively, additives (AD) may be included in the polymeric composition (PC) together with at least one other component. For example, additives (AD) can be added to the polymeric composition (PC) together with polypropylene (PP), polar modified polypropylene (PMP) and/or carbon fibers (CF), preferably in the form of a main batch (MB). Therefore, the terms "polypropylene (PP)", "polar modified polypropylene (PMP)" and "carbon fibers (CF)" can be directed to a composition that includes additives (AD). Additives other than polymeric carrier materials (PCM) are typically added to the polymeric composition (PC) together with polymeric carrier materials (PCM) in the form of a master batch (MB).

[0217] Thus, a polymeric composition (PC) consisting of polypropylene (PP), polar modified polypropylene (PMP) and carbon fibers (CF) may also comprise additives (AD).

Polymeric Carrier Material (PCM)

[0218] As indicated above, in a preferred embodiment, the polymeric composition (PC) does not comprise polymers other than polypropylene (PP) and polar modified polypropylene (PMP) in an amount exceeding 10% by weight, preferably in an amount that exceeds 5% by weight, more preferably, an amount that exceeds 2.5% by weight, even more preferably, an amount that exceeds 0.8% by weight, based on the weight of the polymeric composition ( PRAÇA). If an additional polymer is present, such polymer is typically a polymeric carrier material (PCM) for additives.

[0219] The polymeric carrier material (PCM) is a carrier polymer for the other additives to ensure uniform distribution in the polymeric composition (PC). Polymeric carrier material (PCM) is not limited to a particular polymer. The polymeric carrier material (PCM) can be ethylene homopolymer, ethylene copolymer obtained from ethylene and α-olefin comonomer such as C3 to C8 α-olefin comonomer, propylene homopolymer, propylene copolymer obtained from propylene and α-olefin comonomer such as ethylene and/or C4 to C8 α-olefin comonomer and mixtures thereof.

[0220] Typically, the polymeric carrier material (PCM) as such does not contribute to the improved properties of the described polymeric composition (PC).

The article

[0221] The present invention is further directed to an article comprising the polymeric composition (PC).

[0222] The article may comprise the polymeric composition (PC) in an amount of at least 80% by weight, such as 80 to 99.9% by weight, preferably, in an amount of at least 90% by weight, such as 90 to 99.9% by weight, more preferably, in an amount of at least 95% by weight, such as 95 to 99.9% by weight.

[0223] The article may be a molded article or extruded article, preferably, the article is a molded article, such as an injection molded article or a compression molded article.

EXAMPLES 1. Definitions/Measurement Methods

[0224] The following definitions of terms and methods of determination apply to the above general description of the invention, as well as the examples below, unless otherwise defined. Quantification of Microstructure by NMR Spectroscopy

[0225] Quantitative nuclear magnetic resonance (NMR) spectroscopy is used to quantify the isotacticity and regioregularity of polypropylene homopolymers.

[0226] Quantitative 13C{1H} NMR spectra were recorded in the solution state using a Bruker Advance III 400 NMR spectrometer operating at 400.15 and 100.62 MHz for 1H and 13C, respectively. All spectra were recorded using an optimized 10 mm extended temperature probe head optimized for 13C to 125°C using nitrogen gas for all tires.

[0227] For polypropylene homopolymers, approximately 200 mg of material was dissolved in 1,2-tetrachloroethane-d2 (TCE-d2). To ensure a homogeneous solution, after initial sample preparation on a heat block, the NMR tube was further heated in a rotating oven for at least 1 hour. Upon insertion into the magnet, the tube was rotated at 10 Hz. This configuration was chosen mainly for the high resolution necessary for quantifying tacticality distribution (Busico, V., Cipullo, R., Prog. Polym. Sci. 26 (2001) 443; Busico, V.; Cipullo, R., Monaco, G., Vacatello, M., Segre, A. L., Macromolecules 30 (1997) 6251). Standard single-pulse excitation was employed using the NOE and dual-level WALTZ16 decoupling scheme (Zhou, Z., Kuemmerle, R., Qiu, X., Redwine, D., Cong, R., Taha, A., Baugh, D. Winniford, B., J. Mag. Reson. 187 (2007) 225; Busico, V., Carbonniere, P., Cipullo, R., Pellecchia, R., Severn, J., Talarico, G. , Macromol. Rapid Commun. 2007, 28, 11289). A total of 8192 (8k) variables were acquired by spectra.

[0228] The quantitative 13C{1H} NMR spectra were processed, integrated and the relevant quantitative properties determined from the integrals using private computer programs.

[0229] For polypropylene homopolymers, all chemical shifts are internally relative to the methyl isotactic pentad (mmmm) at 21.85 ppm.

[0230] Characteristic signs corresponding to regiodefects (Resconi, L., Cavallo, L., Fait, A., Piemontesi, F., Chem. Rev. 2000, 100, 1253; Wang, W-J., Zhu, S., Macromolecules 33 (2000), 1157; Cheng, H. N., Macromolecules 17 (1984), 1950) or comonomer were observed.

[0231] The tacticality distribution was quantified by integrating the methyl region between 23,619.7 ppm with correction of any sites unrelated to the stereo sequences of interest (Busico, V., Cipullo, R., Prog. Polym. Sci. 26 (2001) 443; Busico, V., Cipullo, R., Monaco, G., Vacatello, M., Segre, A. L., Macromolecules 30 (1997) 6251).

[0232] Specifically, the influence of regiodefects and comonomer on the quantification of tacticity distribution was corrected by subtracting representative regiodefect and comonomer integrals from the specific integral regions of the stereo sequences.

[0233] Isotacticity was determined at the pentad level and reported as the percentage of isotactic pentad sequences (mmmm) relative to all pentad sequences: [mmmm] % = 100 * (mmmm / sum of all pentads)

[0234] The presence of 2.1 erythro regiodefects was indicated by the presence of the two methyl sites at 17.7 and 17.2 ppm and confirmed by other characteristic sites. The characteristic signs corresponding to other types of regiodefects were not observed (Resconi, L., Cavallo, L., Fait, A., Piemontesi, F., Chem. Rev. 2000, 100, 1253).

[0235] The amount of 2.1 erythro regiodefects was quantified using the average integral of the two characteristic methyl sites at 17.7 and 17.2 ppm: P21e = (le6 + Ie8)/ 2

[0236] The amount of primary propene 1,2 inserted was quantified based on the methyl region with correction performed for sites included in this region unrelated to the primary insertion and for primary insertion sites excluded from this region: P12 = ICH3 + P12e

[0237] The total amount of propylene was quantified as the sum of inserted primary propylene and all other regiodefects present: Ptotal = P12 + P21e

[0238] The mol percentage of 2.1 erythro regiodefects was quantified relative to all propylene: [21e] mol% = 100 * (P21e / Ptotal)

[0239] Characteristic signals corresponding to ethylene incorporation were observed (as described in Cheng, H. N., Macromolecules 1984, 17, 1950) and the comonomer fraction calculated as the fraction of ethylene in the polymer with respect to all monomers in the polymer.

[0240] The comonomer fraction was quantified using the W-J method. Wang and S. Zhu, Macromolecules 2000, 33 1157, Petition 870200029206, dated 03/04/2020, p. 69/85 through the integration of multiple signals across the entire spectral region in the 13C{1H} spectra. This method was chosen for its robust nature and ability to account for the presence of regiodefects when necessary. The integral regions have been slightly adjusted to increase applicability across the entire range of comonomer content found.

[0241] Comonomer incorporation in mole percent was calculated from the mole fraction.

[0242] Comonomer incorporation in weight percent was calculated from the mole fraction.

[0243] Xylene Cold Solubles (XCS) are measured at 25 °C in accordance with ISO 16152; first edition; 2005-07-01.

[0244] Intrinsic Viscosity is measured according to DIN ISO 1628/1, October 1999 (in Decalina at 135 °C).

[0245] Tensile Modulus (TM) is measured in accordance with ISO 527-2 (indent speed = 1 mm/min; 23 °C) using injection molded specimens as described in EN ISO 1873-2 (bone shape dog, 4 mm thick).

[0246] Tensile Strength (TS) and Tensile Elongation at Break (TE) are measured in accordance with ISO 527-2 (indent speed = 50 mm/min; 23 °C) using injection molded specimens as described in EN ISO 1873-2 (dog bone shape, 4 mm thick).

[0247] Flexural Modulus was determined in 3-point bending in accordance with ISO 178 on 80x10x4 mm injection molded specimens prepared in accordance with ISO 2941:1996.

[0248] Charpy Impact Resistance (IS) is determined in accordance with ISO 179 1eU at 23 °C when using a Petition 870200029206, dated 03/04/2020, p. 70/85 injection molded test bar 80x10x4 mm3 in line with EN ISO 1873-2.

[0249] Charpy Notch Impact Resistance (NIS) is determined in accordance with ISO 179 1eA at 23 °C when using an 80x10x4 mm3 injection molded test bar in line with EN ISO 1873-2.

[0250] The Average Fiber Diameter is determined in accordance with ISO 1888:2006(E), Method B, microscopic magnification of 1000.

[0251] Melt Flow Rate (MFR2) is measured in accordance with ISO 1133 at the given temperature and load.

[0252] The Melt Flow Volume Rate (MVI) is measured in accordance with ISO 1133 at the given temperature and load.

[0253] The Heat Deformation Temperature (HDT) is determined in accordance with ISO 75-2 using a Ceast 6921 from Instron® GmbH, Germany.

[0254] Density is measured in accordance with ISO 1183-187. Sample preparation is done by compression modeling in accordance with ISO 1872-2:2007.

[0255] DSC Analysis, Melting Temperature (Tm) and Melting Enthalpy (Hm), Crystallization Temperature (Tc) and Crystallization Enthalpy (Hc) are measured with a TA Q200 scanning calorimetry instrument differential (DSC) in 5 to 7 mg samples. DSC is performed according to ISO 11357 / part 3 / method C2 in a heat/cold/heat cycle with a scan rate of 10 °C/min in the temperature range from -30 to +225 °C. The crystallization temperature and enthalpy of crystallization (Hc) are determined from the cooling step, while the melting temperature and enthalpy of fusion (Hm) are determined from the second heating step.

[0256] Injection Pressure (INJP) is measured during injection molding of the specimens used to determine flow marks as described below with respective process conditions on an Engel ES 1350/350 HL injection molding apparatus.

The Flow Marks

[0257] The tendency to show flow marks was examined with a method as described below. This method is described in detail in document WO 2010/149529, which is incorporated herein in its entirety.

[0258] An optical measurement system, as described by Sybille Frank et al. in PPS 25 Intern. Conf. Polym. Proc. Soc 2009 or Proceedings of the SPIE, Volume 6831, pp 68130T-68130T-8 (2008), was used to characterize surface quality.

[0259] This method consists of two aspects:

1. Image recording:

[0260] The basic principle of the measurement system is to illuminate the plates with a defined light source (LED) in a closed environment and record an image with a CCD camera system.

[0261] A schematic configuration is given in Figure 1.

2. Image Analysis:

[0262] The specimen is illuminated on one side and the upwardly reflected portion of the light is deflected through two mirrors to a CCD sensor. The gray value image created consequently is analyzed into lines. From the recorded deviations of gray values, the mean squared error (MSE) is calculated allowing a quantification of surface quality, that is, the higher the MSE value the more pronounced the surface defect.

[0263] In general, for the same material, the tendency to flow marks increases when the injection speed is increased.

[0264] For this evaluation, 440x148x2.8 mm plates with VW K50 grain and a 1.4 mm film port were used and were produced with a fill time of 3 seconds.

[0265] Additional conditions: Melting temperature: 240 °C Mold temperature 40 °C Dynamic pressure: 1 MPa (10 bar) hydraulic.

[0266] The lower the MSE value is at a certain filling time, the lower the tendency to flow marks. Process Conditions: Melting temperature: 240 °C. Mold temperature 40 °C. Dynamic pressure: 1 MPa (10 bar) hydraulic.

2. Examples

[0267] The present invention is illustrated by the following examples:

[0268] Inventive Examples IE1 to IE4 are prepared by melt blending with a twin-screw extruder such as the Coperion STS-35 twin-screw extruder from Coperion Corporation (Nanjing), China. The twin-screw extruder operates at a medium screw speed of 400 rpm with a temperature profile of zones from 180 to 250 °C.

[0269] Inventive Example IE1 and Comparative Examples CE1 and CE2 are based on the recipe summarized in Table 2. Table 1: The recipe for preparing the inventive and comparative compositions * remaining to 100% by weight are additives at regular levels, including polymeric carrier material, antioxidants and UV stabilizers such as pentaerythrityl-tetrakis(3-(3',5'-di-tert.butyl-4-hydroxyphenyl)-propionate in the form of the commercial antioxidant “Irganox 1010” from BASF, Germany, CAS No. 6683-19-8; and tris(2,4-di-t-butylphenyl)phosphite in the form of the commercial antioxidant “Irgafos 168 FF” from BASF, Germany, CAS No. 31570-04-4.

[0270] "PPH-1" is the commercial product HF955MO from Borealis AG, which is a propylene homopolymer having an MFR2 melt flow rate (230 °C, 2.16 kg) of 20 g/10 min and a density of 908 kg/m3. HF955MO propylene homopolymer is an α-nucleated polyvinyl cyclohexane.

[0271] "PPH-2" is the commercial product HJ120UB from Borealis AG, which is a propylene homopolymer having an MFR2 melt flow rate (230 °C, 2.16 kg) of 75 g/10 min and a density of 905 kg/m3.

[0272] "PPH-3" is the commercial product HL504FB from Borealis Petition 870200029206, dated 03/04/2020, p. 74/85 AG, which is a propylene homopolymer that has an MFR2 melt flow rate (230 °C, 2.16 kg) of 450 g/10 min.

[0273] "Elastomer-1" is the commercial product Queo8201 from Borealis AG, which is an ethylene/1-octene copolymer that has an MFR2 melt flow rate (190 °C, 2.16 kg) of 1.1 g/10 min and a density of 883 kg/m3.

[0274] "Elastomer-2" is the commercial product Queo8230 from Borealis AG, which is an ethylene/l-octene copolymer that has an MFR2 melt flow rate (190 °C, 2.16 kg) of 30 g/ 10 min and a density of 882 kg/m3.

[0275] "PMP” is the product SCONA TSPP10213GB from Co. Ltd, Germany, which is a propylene functionalized maleic acid anhydride having an MVR (170 °C, 1.2 kg) of 40 to 100 cm3/10 min and a maleic acid anhydride content of 2.0% by weight.

[0276] "CF” is the commercial product RECATEX C90 from SGL Carbon SE, which is a non-woven cloth comprising 90% by weight carbon fiber having a density determined in accordance with ISO 10119:2002 of 1.8 g /m3 and a tensile strength determined in accordance with ISO 10618:2004 of 4400.

[0277] The properties of Inventive Examples IE1 to IE4 and Comparative Example CE1 are summarized in Table 2. Table 2: The properties of the inventive and comparative compositions (ranges of claim 1 are also given)

Claims (7)

1. Polymeric composition (PC) characterized by having - an MFR2 melt flow rate (230 °C, 2.16 kg) measured in accordance with ISO 1133 in the range of 20 to 30 g/10 min, - a tensile modulus measured in accordance with ISO 527-2 in the range of 8500 to 11500 MPa, - a Charpy Impact Strength measured in accordance with ISO 179-leU:2000 at 23 °C in the range of 30 to 50 kJ/m2 and - an elongation tensile strength measured in accordance with ISO 527-2 in the range of 2.0 to 5.0% comprising (a) 55 to 95 parts by weight of a polypropylene (PP) composition; (b) 2.5 to 10 parts by weight of a polar modified polypropylene (PMP) comprising polar groups in an amount in the range of 1.5 to 3.0% by weight based on the total weight of the polar modified polypropylene (PMP) ; (c) 2.5 to 35 parts by weight of carbon fibers (CF); based on total parts by weight of compounds (a), (b) and (c), wherein the polypropylene (PP) composition comprises: (a1) 6 to 19 parts by weight of a first propylene homopolymer (PPH -1) having an MFR2 melt flow rate (230°C, 2.16 kg) measured in accordance with ISO 1133 in the range of 1.0 to 45 g/10 min; (a2) 43 to 85 parts by weight of a second propylene homopolymer (PPH-2) having a melt flow rate MFR2 (230°C, 2.16 kg) measured in accordance with ISO 1133 in the range of 50 to 190 g/10 min; (a3) 6 to 19 parts by weight of a third propylene homopolymer (PPH-3) having a melt flow rate MFR2 Petition 870220072960, dated 08/15/2022, p. 8/21 (230°C, 2.16 kg) measured according to ISO 1133 in the range of 200 to 800 g/10 min; and (a4) 6 to 19 parts by weight of random ethylene copolymer (RPE), wherein the random ethylene copolymer (RPE) is an elastomeric copolymer consisting of units derivable from ethylene and units derivable from at least one alpha-olefin C3 to C10; all parts by weight based on the total parts by weight of compounds (a1), (a2), (a3) and (a4) or wherein the polypropylene (PP) composition comprises: (a1) 5 to 25 parts per weight of a first propylene homopolymer (PPH-1) with a melt flow rate MFR2 (230°C, 2.16 kg) measured according to ISO 1133 in the range of 1.0 to 45 g/10 min; (a2) 15 to 50 parts by weight of a second propylene homopolymer (PPH-2) with a melt flow rate MFR2 (230°C, 2.16 kg) measured in accordance with ISO 1133 in the range of 50 to 190 g/10 min; (a3) 5 to 25 parts by weight of a third propylene homopolymer (PPH-3) having a melt flow rate MFR2 (230°C, 2.16 kg) measured in accordance with ISO 1133 in the range of 200 to 800 g/10 min; and (a5) 20 to 60 parts by weight of heterophasic propylene copolymer (HECO); all parts by weight based on the total parts by weight of compounds (a1), (a2), (a3) and (a5). 2. Polymeric composition (PC), according to claim 1, characterized by the fact that the polypropylene (PP) composition and polar modified polypropylene (PMP) are comprised in an amount of at least 75% by weight, based in the total weight of the polymeric composition (PC). 3. Polymeric composition (PC), according to any one of claims 1 or 2, characterized by the fact that the polypropylene composition (PP), polar modified polypropylene (PMP) and carbon fibers (CF) are comprised in an amount of at least 89% by weight, based on the total weight of the polymeric composition (PC). 4. Polymeric composition (PC) according to any one of the preceding claims, the polymeric composition (PC) being characterized by having (a) a tensile strength measured according to ISO 5272 of at least 60 MPa and/or (b ) a flexural modulus measured according to ISO 178 of at least 5000 MPa. 5. Polymeric composition (PC), according to any one of the preceding claims, the polymeric composition (PC) being characterized in that it does not comprise (a) any fibers other than carbon fibers (CF). 6. Polymeric composition (PC), according to any one of the preceding claims, characterized by the fact that polypropylene (PP) does not comprise any other polymer other than (a) the propylene homopolymer (PPH-1), the homopolymer of propylene (PPH-2), propylene homopolymer (PPH-3) and random ethylene copolymer (RPE); or (b) the propylene homopolymer (PPH-1), the homopolymer of (a) the propylene homopolymer (PPH-1), the propylene homopolymer (PPH-2), the propylene homopolymer (PPH-3) and random ethylene copolymer (RPE); or (b) propylene homopolymer (PPH-1), propylene homopolymer (PPH-2), propylene homopolymer (PPH-3) and heterophase propylene copolymer (HECO). 7. Article characterized by comprising a polymeric composition (PC) as defined in any of the previous claims.