WO2018017573A1

WO2018017573A1 - Flame retardant glass-filled polypropylene compositions and articles formed from the same

Info

Publication number: WO2018017573A1
Application number: PCT/US2017/042604
Authority: WO
Inventors: Michael M. Laurin; Craig Lawrence Milne; Rein Mollerus Faber; Manish Nandi; Christianus Johannes Jacobus Maas; Hochul JUNG; Mohammad Moniruzzaman
Original assignee: Sabic Global Technologies B.V.
Priority date: 2016-07-21
Filing date: 2017-07-18
Publication date: 2018-01-25

Abstract

An enclosure formed from a thermoplastic composition includes: a homopolymer component including polypropylene, a copolymer component including polypropylene, or a combination thereof; an impact modifier; a flame retardant component; and a fiber reinforcement component. The enclosure is configured to house an electrical component. Articles for a medical application are also described.

Description

FLAME RETARDANT GLASS-FILLED POLYPROPYLENE COMPOSITIONS AND ARTICLES FORMED FROM THE SAME

FIELD

[0001] The present disclosure relates to flame retardant glass-filled polypropylene compositions, articles, and methods of making the same.

BACKGROUND

[0002] Glass fiber is typically added to semi-crystalline materials, such as, for example, polypropylene materials, to maintain or improve dimensional stability under extreme temperatures. Unfortunately, the addition of glass fiber also results in diminished elastic properties. Similarly, long fiber reinforcements in thermoplastic resin can improve impact properties of the product. Presence of the long fibers in the composite, however, can also result in an unwanted brittleness of the composite, which can limit its applicability due to performance concerns.

[0003] Accordingly, there remains a need for thermoplastic compositions and methods of forming article from the same that can provide improved impact strength properties and other improved properties including the ability to be sterilized for medical applications. These needs and other needs are satisfied by the compositions, articles, and methods of the present disclosure.

SUMMARY

[0004] Aspects of the disclosure relate to an enclosure formed from a thermoplastic composition including: a homopolymer component including polypropylene, a copolymer component including polypropylene, or a combination thereof; an impact modifier; a flame retardant component; and a fiber reinforcement component. The enclosure is configured to house an electrical component.

[0005] Aspects of the disclosure further relate to an article for a medical application.

[0006] The article includes in some aspects: a composition including pellets of a flame retardant fiber-reinforced polypropylene composition having a core including fibers and a sheath of a polypropylene compound including a flame retardant composition and surrounding the core. The flame retardant composition includes a mixture of an organo phosphorous compound, an organic phosphoric acid compound and zinc oxide.

[0007] The article includes in other aspects a composition including: pellets of a fiber- reinforced polypropylene composition having a core including fibers and a sheath of a first polypropylene compound surrounding the core, wherein the fiber-reinforced polypropylene composition includes 10-70 % by total weight of the fiber-reinforced polypropylene composition of fibers and 30-90 % by total weight of the fiber-reinforced polypropylene composition of polypropylene compound, the fiber-reinforced polypropylene composition not containing a flame retardant composition; and a flame retardant polypropylene dilution composition including a second polypropylene compound containing a flame retardant composition including a mixture of an organo phosphorous compound, an organic phosphoric acid compound and zinc oxide.

[0008] The article includes in further aspects a composition including: pellets of a flame retardant fiber-reinforced polypropylene composition having a core including fibers and a sheath of a polypropylene compound including a flame retardant composition and surrounding the core, wherein the flame retardant composition includes a mixture of an organo phosphorous compound, an organic phosphoric acid compound and zinc oxide; and a flame retardant polypropylene dilution composition including a second polypropylene compound containing a flame retardant composition including a mixture of an organo phosphorous compound, an organic phosphoric acid compound and zinc oxide.

DETAILED DESCRIPTION

[0009] Fiber-reinforced thermoset plastics have traditionally been used in performance demanding applications, including but not limited to aerospace applications. Recently, however, the medical industr has started looking at fiber-filled thermoplastic composites due to their improved ductility and impact resistance, thermoformability, shorter production cycle, and recyclability. These improvements increase the likelihood of articles meeting government regulations. Additionally, these improvements are cost-effective, a feature that may be important to medical device manufacturers. As a particular example, articles may include enclosures for electronic devices or electrical components. The enclosures may include the compositions described herein. Moreover, the enclosures may be chemically resistant to certain solvents and cleaners, for example surgical cleaners used in medical environments.

[0010] To obtain optimum performance of thermoplastic-based composite, it may be desirable to use polypropylene (PP) reinforced with glass fibers (GF). Such GF-PP composite typically is readily available, thus making it very economical, and in application, demonstrates improved impact resistance in automobile bumpers and lateral door supports, for example.

[0011] The performance of GF-PP can be determined by the properties of the PP, the glass fibers, and the interface between them. PP is a semi-crystalline thermoplastic in which the crystalline phase plays a critical role in defining the macroscopic properties of the entire composite. Crystallization is a thermodynamic process that depends mainly on the cooling rate during the last stage of the manufacturing cycle. Rapid cooling is certainly beneficial to composites manufacturers because the total processing time can be reduced. However, it is important to understand how the heating and cooling affects the mechanical properties of the resulting PP and its composites.

[0012] it has been shown that the cooling rate affects both the crystallinity (ratio of the crystalline phase to the amorphous phase) and the morphology (the size of crystals, which are usually called spherulites). Generally, increasing the cooling rate reduces both the crystallinity and the size of spherulites in neat homopolymer PP and its composites. These reductions impact the mechanical performance of GF-PP: increasing the cooling rate improves the fiexural strength, in-plane shear stre gth, strain at failure, and tensile/opening (mode I) and in-plane shear (mode Π) fracture toughness.

[0013] It has further been shown that the cooling rate also affects the fiber-matrix interface of classical GF-PP. Scanning electron microscope (SEM) observation of failed GF- PP laminates reveals that most of the damage in rapidly cooled samples occurs in the bulk PP matrix, while the damage in slowly cooled samples is mostly characterized by fiber-matrix debonding. These observations substantiate the results of single fiber pull-out tests, which show that the fiber-matrix mterfacial shear strength (IFSS) of a glass fiber in quenched PP is higher than that of a glass fiber in isothermally crystallized PP at a dwelling temperature of 140 degrees Celsius (°C). [0014] Moreover, the mechanisms used in applying heat to a plaque for forming various articles may be optimized. For example, pressurized halogen heaters may be used to apply heat to a plaque formed from compositions described herein. Pressurized halogen heaters may comprise halogen gas that is pressurized and produces intense heat. As another example, the heaters may have maximum operating temperature between 1500 - 3000 °C and maximum intensity between 0.80 micrometers (microns, μηι) and 2 μιτι. As a further example, the heaters may have maximum operating temperature at about 2700 °C and maximum intensity at about 0.90 μιτι. Further, the heater profile may be optimized or configured for surface area heating at a perimeter of plaque such that the center heat minimizes plaque thinning and radius stretch through side walls, thereby retaining maximum wall thickness.

[0015] As briefly summarized above, aspects of the present disclosure provide fiber- reinforced thermoplastic polymer compositions that exhibit one or more improved performance properties relative to conventional reinforced thermoplastic compositions. For example, the disclosed fi er-reinforced thermoplastic polymer compositions can exhibit one or more of improved impact properties, improved ductile failure mode, and can exhibit a softer touch or feel along with a relatively low surface gloss. To that end, as one of ordinary skill in the art will appreciate, conventional reinforced thermoplastic materials typically contain a thermoplastic material that has been blended with glass reinforcing fibers to i mpart rigidity and improve impact strength as evidenced, for example, by a general increase in tensile strength and modulus. However, the addition of reinforcin glass fibers also typically reduces the elastic properties of the thermoplastic material as evidence, for example, by a reduced ductility or tensile elongation or strain.

[0016] As noted above, the disclosed compositions comprise a thermoplastic polymer component. The thermoplastic polymer component comprises at least one thermoplastic polymer. In one aspect, the thermoplastic polymer component can comprise a single thermoplastic polymeric material or. alternatively, in another aspect can comprise a blend of two or more di ferent thermoplastic polymer materials. The thermoplastic polymer component can comprise any thermoplastic polymer or mixture of polymers suitable for use in the composition or in an intended application. According to some aspects, the

thermoplastic polymer component comprises a polypropylene polymer component. For example, in some aspects the polypropylene component can comprise a polypropylene homopolymer. According to an exemplary non-limiting aspect, a commercially available polypropylene homopolymer suitable for use in the compositions and methods disclosed and described herein is the Innovene™ H20H grade polypropylene available from Ineos Technologies. The Innovene™ H20H grade polypropylene has a melt flow index (MFI) of about 20 grams per 10 minutes (g/10 min) when measured at a temperature of 230 °C and under a 2.16 kilogram (kg) load. In a still further exemplary and non-limiting aspect, one or more of a low flow and high flow grade thermoplastic polymer may be used. Generally, a low flow grade thermoplastic polymer may be described as one having a MFI of less than 20 g/10 min when measured at a temperature of 230 °C and under a 2.16 kg load, and a high fl ow grade thermoplastic polymer may be described as one having a MFI of greater than or equal to 20 g/10 min when measured at a temperature of 230 °C and under a 2. 16 kg load. In one aspect, a low flow PP may include Bapolene® 4042 polypropylene resin (Bamburger Polymers, Inc., MFI of about 4 g/10 minutes when measured at a temperature of 230 °C and under a 2.16 kg load) and a high flow PP may include Bapolene® 4082 polypropylene resin (Bamburger Polymers, Inc., MFI of about 35 g/10 minutes when measured at a temperature of 230 °C and under a 2.16 kg load). As an example, a blend of Bapolene® 4042 low flow PP and Bapolene® 4082 high flow PP may be mixed (with or without other

components additives) to result in a polypropylene with a MFR of between 14 and 18 g/10 minutes when measured at a temperature of 210 °C and under a 5 kg load. Loadings of one or more of the low flow and high flow materials may include 30% high flow and 70% low flow relative to the PP blend and 50% low flow with 30% high flow including the remaining 20% of additives and other components resulting in 100% wt of the overall blended composition.

10017] Alternatively, the polypropylene component can comprise a polypropylene copolymer. The thermoplastic polymer component can be present in the composition in any desired amount. However, in some aspects the thermoplastic polymer component be present in the composition in an amount in the range of from about 10 weight percent* wt. %) to 90 wt. % of the composition, including such exemplary amounts as 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, or 85 wt. %. In still further aspects, the thermoplastic polymer component can be present in an amount within any range deri ed from any two of the above values, including for example, an amount in the range of from 10 wt % to 70 wt. %, or an amount in the range of from 20 wt. % to 70 wt. %. [0018j As also noted above, the disclosed compositions further comprise a low melt flow elastomer component. The low melt flow elastomer component can be characterized by having a melt flow index (MFI) value less than 30 g/ 0 minutes when measured at a temperature of 190 °C and under a 2.16 kg load. In further aspects, the low melt flow elastomer component can exhibit a melt flow index value less than 25 g/10 minutes, less than 20 g/10 minutes, less than 15 g/10 minutes, less than 10 g/10 minutes, or even less than 5 g/10 minutes when measured at a temperature of 190 °C and under a 2.16 kg load. In still further aspects, the low melt flow elastomer component exhibits a melt flow index in any range derived from any two of the above disclosed melt flow index values, including for example, a melt flow index in the range of from 5 to 20 g/10 minutes when measured at a temperature of 190 °C and under a 2.16 kg load. As used herein, melt flow index values can, for example and without limitation, be determined according to the ASTM D1238 testing protocol.

[0019] Exemplar)' low melt flow elastomers suitable for use in the disclosed

compositions include the class of ethylene containin elastomers, incl udin for example ethy lene-butene copolymer elastomers and ethylene-octene copolymer elastomers. Similar to the thermoplastic polymer component, the low melt flow elastomer component can comprise a single low melt flow elastomer or, alternatively, can comprise a blend of two or more di fferent low melt flow elastomers. Further, although the low melt flow elastomer component can be present in the composition in any desired amount, it may be desirable according to some aspects for the low melt flow elastomer component to be present in the composition in an amount in the range of from greater than 0 wt. % to 30 wt. %, including exemplary amounts of 1 wt. %, 5 wt. %, 10 wt. %, 15 wt. %, 20 wt. %, and 25 wt. %. In still further aspects, the low melt flow elastomer component can be present in the composition in an amount in any range derived from any two of the above disclosed wt. % values, including for example from 5 to 20 wt. % or from 10 to 20 wt. %. An exemplary non-limitin example of a commercially available ethylene-butene elastomer suitable for use in the compositions and methods disclosed herein is the Engage™ 7447 available from Dow Chemicals. Exemplary non-limiting examples of commercially available ethylene-octene elastomers suitable for use in the compositions and methods disclosed herein include Engage™ 8200, Engage™ 8137 and Engage™ 8407, all of which are also available from Dow Chemicals. [0020J The disclosed compositions further comprise a fiber reinforcement component. In certain aspects the fiber reinforcement component comprises a plurality of glass fibers. To that end, the glass fibers can be relatively short glass fibers, relatively long glass fibers, or a combination of both short and long glass fibers. As used herein, the term short glass fibers refers to a population of glass fibers having an average fiber length less than or equal to about 5 millimeters (mm). As used herein, the term long glass fibers refers to a population of glass fibers having an average fiber length greater than about 5 mm. including for example, a population of glass fibers havin a fiber length in the range of from greater than 5 mm to 15 mm. The fiber reinforcement component can be present in the composition in any desired amount. However, in some aspects, the reinforcement component can be present in the composition in an amount from greater than 0 wt. % to about 70 wt. %, including exemplar) amounts of 5 wt. %, 10 wt. %, 15 wt. %, 20 wt. %, 25 wt. %, 30 wt. %, 35 wt. %, 40 wt. %, 45 wt. %, 50 %, 55 wt. %, 60 wt. %, and 65 wt %. In still further aspects, the fiber reinforcement component can be present in the composition in an amount in any range derived from any two of the above disclosed wt. % values, including for example from 20 to 50 wt. % or from 30 to 50 wt. %. Exemplar long glass fibers include, without limitation, TufRov® 4588 glass fibers commercially available from PPG Industries. Exemplary short or chopped glass fibers suitable for use in disclosed samples, including those prepared by twin screw extrusion compounding as exemplified herein, include without limitation the

ThermoFlow™ 738 glass fibers commercially available from Johns Manville.

[0021] The disclosed compositions can further comprise one or more optional additive components, including for example, one or more additive selected from the group consisting of a coupling agent, antioxidant, heat stabilizer, flow modifier, and colorant. For example, and without limitation, an exemplary coupling agent suitable for use as an additive component in the disclosed compositions includes the Polybond™ 3150 maleic anhydride grafted polypropylene commercially available from Chemtura or the Fusabond™ P613 maleic anhydride grafted polypropylene commercially available from DuPont. An exemplary flow modifier suitable for use as an additive component in the disclosed compositions can include, without limitation, the C 20P peroxide masterbatch commercially available from Poly \ el Inc. Still further, an exemplary stabilizer suitable for use as an additive component in the disclosed compositions can include, without limitation, the Irganox™ B225 commercially available from BASF. In a still further aspect, neat polypropylene can be introduced as an optional additive. For example, neat polypropylene can be introduced in a diy blending step during a molding process to alter levels of glass fiber loading in a composition.

[0022] According to aspects of the disclosure, the disclosed fiber-reinforced

thermoplastic polymer compositions can exhibit one or more improved performance properties when compared to a conventional or reference composition in the absence of the low melt flow elastomer component. For example, the disclosed compositions can exhibit one or more of improved impact properties, more ductile and less brittle failure modes, a softer touch or feel, and a relatively low surface gloss. Further, it should be understood that these improved properties relative to the comparative reference compositions can be provided in any combination or they can occur indi vidual ly for a given composition.

[0023] In still further aspects, the present disclosure provides methods for the manufacture of the fiber-reinforced thermoplastic compositions described herein. For example, and without li mitation, a thermoplastic resin mixture can be provided that comprises a polypropylene polymer component and a reinforcement component.

[0024] A provided reinforcing fiber component as described above can then be contacted with the thermoplastic resin mixture to provide a fiber-reinforced thermoplastic composite. As one of ordinary skill in the art will appreciate, this contactin step can vary dependin upon the nature of the reinforcing fiber component. For example, according to some aspects the contacting step can be performed by a continuous one step pultrusion process. As one of ordinary skill in the art will appreciate, a pultrusion process is better suited for use in those aspects where the reinforcin fiber material comprises long glass fiber. According to these aspects, glass fiber rovings can be continuously pulled off a spool and through a

thermoplastic resin mixture coating or impregnation station where they are coated or i mpregnated with a melt comprising the thermoplastic resin mixture. The coated or i mpregnated glass fiber strands can then be cooled and subsequently pelleti/ed. These pellets can then be injection molded into test specimen parts in their existing form for property- testing or into molded parts of varying complexity for use in desired end use applications. If one or more optional additives are desired to be incorporated into the fiber-reinforced thermoplastic compositions, they can be introduced either during the pultrusion process or by dry-blending with pelletized reinforced thermoplastic composition following the pultrusion process and before any subsequent molding steps. |0025| In alternative aspects where the fiber reinforcing material comprises short glass fibers, the step of contacting the short glass fibers with the thermoplastic resin mixture can, for exampl e, be performed by compounding the short glass fibers together with the thermoplastic resin mixture. This compoundin can be performed using any conventionally known equipment used for the manufacture of fiber-reinforced thermoplastic composite materials, including for example the use of a twin screw extruder. The extruded glass fiber- reinforced composition can then be cooled and subsequently pelleti/ed. These pellets can then be injection molded into test specimen parts in their existing form for property testin or into molded parts of varying complexity for use in desired end use applications. Once again, if one or more optional additi es are desired to be incorporated into the fiber-reinforced thermoplastic composition, they can be introduced either during the extmsion process or by dry-blending with pelleti/ed reinforced thermoplastic composition following the extrusion process and before any subsequent molding steps.

[0026] The optional additives disclosed herein can be introduced into the compositions either before or during a molding process. For example, one or more optional additives can be introduced into a thermoplastic resin mixture or composition before glass fiber reinforcement components are blended or otherwise introduced into the thermoplastic resin mixture. Alternatively, one or more optional additives can be introduced into a composition after the glass fiber reinforcement component has been blended or otherwise introduced into a composition. In still further aspects, one or more optional additives can be introduced during a dry blendin step performed during a molding process.

[0027] The fiber-reinforced thermoplastic compositions disclosed and described herein can be used in various end use applications, including in applications where sterilization is required. As an example, a surgical article may be formed comprising a surgical tray including a bottom surface having side walls disposed around a periphery thereof and extending from the bottom surface. The surgical article may be formed using various processes. In certain aspects, vacuum forming may be used. The vacuum forming may include a heater profile optimized or configured to heat a surface area at a perimeter of a plaque such that a plaque thinning at the bottom surface is minimized and radius stretch through the side walls is minimized, thereby retaining maximum wall thickness. Aspects

18\ In various aspects, the present disclosure pertains to and incl udes at least the following aspects.

[0029] Aspect 1 : An enclosure formed from a thermoplastic composition comprising: a) a homopolymer component comprising polypropylene, a copolymer component comprising polypropylene, or a combination thereof; b) an impact modifier; c) a flame retardant component; and d) a fiber reinforcement component, wherein the enclosure is configured to house an electrical component.

100301 Aspect 2: The enclosure of Aspect 1, further comprising one or more additives selected from the group consisting of a coupling agent, heat stabilizer, flow modifier, and colorant.

[0031] Aspect 3 : The enclosure of any one of Aspects 1 -2, wherein the enclosure is chemically resistant to a medical grade cleaner.

100321 Aspect 4: The enclosure of any one of Aspects 1 -3, wherein the homopolymer component comprises one or more of a low flow grade polypropylene and a high flow grade polypropylene.

100331 Aspect 5 : The enclosure of any one of Aspects 1 -4, wherein the copolymer component comprises one or more of a low flow grade polypropylene and a high flow grade polypropylene.

100341 Aspect 6: The enclosure of any one of Aspects 1 -5, comprising from 20 to 90 weight percent of the fiber reinforcement component relative to the weight of the thermoplastic composition. [0035j Aspect 7: The enclosure of any one of Aspects 1-6, wherein the thermoplastic composition has a melt flow rate (MFR) of between 14 and 18 g/10 minutes when measured at a temperature of 210 °C and under 5 kg load,

100361 Aspect 8: The enclosure of any one of Aspects 1-7, wherein the fiber reinforcement component comprises a glass fiber.

|0037| Aspect 9: The enclosure of Aspect 8, wherein the fiber reinforcement component comprises a long glass fiber having a length after extrusion or molding of from about 2 mm to about 15 mm.

[0038] Aspect 10: The enclosure of Aspect 8, wherein the fiber reinforcement component comprises short glass fibers having a length after extrusion or molding of from about 0.1 mm to about 0.2 mm.

100391 Aspect 11 : An article for a medical application, the article comprising: i) a composition comprising pellets of a flame retardant fiber-reinforced polypropylene composition having a core comprising fibers and a sheath of a polypropylene compound comprising a flame retardant composition and surrounding the core, wherein the flame retardant composition comprises a mixture of an organo phosphorous compound, an organic phosphoric acid compound and zinc oxide; ii) a composition comprising: a) pellets of a fiber-reinforced polypropylene composition having a core comprising fibers and a sheath of a first polypropylene compound surrounding the core, wherein the fiber-reinforced polypropylene composition comprises 10-70 % by total weight of the fiber-reinforced polypropylene composition of fibers and 30-90 % by total weight of the fiber-reinforced polypropylene composition of polypropylene compound, the fiber-reinforced polypropylene composition not containing a flame retardant composition, and b) a flame retardant polypropylene dilution composition comprising a second polypropylene compound containing a flame retardant composition comprising a mixture of an organo phosphorous compound, an organic phosphoric acid compound and zinc oxide; or iii) a composition comprising: a) pellets of a flame retardant fiber-reinforced polypropylene composition having a core comprising fibers and a sheath of a polypropylene compound comprising a flame retardant composition and surrounding the core, wherein the flame retardant composition comprises a mixture of an organo phosphorous compound, an organic phosphoric acid compound and zinc oxide, and b) a flame retardant polypropylene dilution composition comprising a second polypropylene compound containing a flame retardant composition comprising a mixture of an organo phosphorous compound, an organic phosphoric acid compound and zinc oxide.

[0040] Aspect 12: The article of Aspect 1 1, wherein the pellets of a flame retardant fiber-reinforced polypropylene composition i) comprise:

25-80 % by total weight of the composition of polypropylene compound;

10-40 % by total weight of the composition of fibers, or

10-35 % by total weight of the composition of a flame retardant composition.

[0041] Aspect 13: The article of Aspect 1 1 or 12, wherein the pellets of fiber-reinforced polypropylene composition ii)a) comprise 15-70 % by total weight of the fiber-reinforced polypropylene composition of fibers.

[0042] Aspect 14: The article of any one of Aspects 11 -13, wherein the pellets of a flame retardant fiber-reinforced polypropylene composition iii) comprise:

35-80 % by total weight of the composition of polypropylene compound;

10 40 % by total weight of the composition of fibers; or

10-35 % by total weight of the composition of a flame retardant composition.

[0043] Aspect 15: The article of any one of Aspects 11 -14, wherein the fibers are selected from the group consisting of glass fibers, basalt fibers, wollastonite fibers, ceramic fibers, slag wool fibers, stone wool fibers, processed mineral fibers from mineral wool, and a combination thereof.

[0044] Aspect 16: The article of any one of Aspects 11-15, wherein the article is an enclosure.

[0045] Aspect 17: The article of any one of Aspects 11-16, wherein the article is configured to house an electrical component.

[0046] Aspect 18: The article of any one of Aspects 11-17, wherein the article is chemically resistant to a medical grade cleaner.

Examples; i) Flame returdani fiber-reinforced polypropylene composition

[0047] In an aspect, an article such as an enclosure for electrical devices/components for us in various environments including surgical and medical environments is obtainable by using pellets of a flame retardant fiber-reinforced polypropylene composition.

[0048] As an example, the pellets of the flame retardant fiber-reinforced polypropylene composition may include: 25-80 % by total weight of the composition of polypropylene compound; 10-40 % by total weight of the composition of fibers; and 10-35 % by total weight of the composition of a flame retardant composition.

[0049] The polypropylene can be a propylene homopolymer. a propylene-a-olefin copolymer, such as a propylene-ethylene random copolymer, an impact propylene copolymer, sometimes referred to as a heterophasic propylene copolymer, or a propylene block-copolymer. Mixtures of more than one polypropylene are also possible. Which type of polypropylene is used depends on the intended application. In some aspects it may be desirable to use either a polypropylene homopolymer for applications requiring high stiffness or a heterophasic propylene copolymer for applications that require good stiffness in combination with good impact properties.

[0050] The polypropylene compound typically has a melt flow index (MFI) that is significantly lower as compared to polypropylene compounds used in pultrusion processes. As such the melt flow index of the polypropylene compound may be 5-100 grams per 10 minutes (g/10 min) (as measured at 230 °C under 2.16 kg force according to ISO 1 133 ). or 10-100 g/10 min, or 10-80 g/10 min, or even 20-80 g/10 min. Other ranges of MFI may be used, as described herein. As a parti cular example, blends of materials may be used to result in MFI of 10- 18 g/10 min.

[0051] T he polypropylene compound may further comprise a flame retardant composition comprising a mixture of an organo-phosphorous compound, an organic phosphoric acid compound, zinc oxide, and optionally a nitrogen-containing compound. For the avoidance of doubt the flame retardant composition is a halogen-free flame retardant composition.

|0052| In such mixture, the weight ratio of organ o- ph os ph oro us compound to phosphoric acid compound may range from 1 :0.01 to 1 :3. In some aspects the weight ratio ranges from 1 :0.5 to 1 :2.5, such as from 1 : 1 to 1 :2.

[0053] Suitable organo-phosphorous compounds that may be used in the mixture include organic phosphate compounds such as piperazine pyrophosphate, piperazine polyphosphate and combinations thereof.

[0054] Suitable phosphoric acid compounds that may be used in the mixture include, but are not limited to, phosphoric acid, melamine pyrophosphate, melamine polyphosphates, melamine phosphate and combinations thereof In a particular aspect the phosphoric acid compound is melamine phosphate.

[0055] Suitable nitrogen-containing compounds include melamine. pipera/ine, and the like. Also combinations of nitrogen-containing compounds may be used. Some examples mentioned above for suitable organo-phosphorous compounds and phosphoric acid compounds (such as piperazine pyrophosphate, piperazine polyphosphate, melamine pyrophosphate, melamine polyphosphate, and melamine phosphate) already comprise such nitrogen-containing compound.

[0056] The zinc oxide may in some aspects be included in an amount of 2-10 % by total weight of the flame retardant fiber-reinforced polypropylene composition, and in particular aspects from 3-6 %. [0057J An example of a commercially available flame retardant composition is ADK STAB FP-2200, available from Adeka Pal marole.

[0058] Flame retardancy can be tested using the UL-94 standard, which is the commonly accepted Standard for Safety of Flammability of Plastic Materials for Parts in Devices and Appliances testing. In this standard, vertical ratings, V2, VI and V0 indicate that the material was tested in a vertical position and self-extinguished within a specified time after the ignition source was removed. The vertical ratings also indicate whether the test specimen dripped flaming particles that ignited a cotton indicator located below the sample. The amount of flame retardant composition can be 10-35 % by total weight of the flame retardant fiber-reinforced polypropylene composition. Higher amounts, such as from 20-35 %, may be used for applications that need to be compliant with a UL-94 5V rating. For ULS-94 V0 ratings, lower amounts of flame retardant composition may suffice.

[0059] T he poK propylene compound may further comprise additives and or stabilizers such as antioxidants, ultraviolet stabilizers, flame retardants (including magnesium hydroxide, aluminum trihydrate, and the like), pigments, dyes, adhesion promoters (such as modified polypropylene, in particular maleated polypropylene), antistatic agents, mold release agents, nucleating agents and the like. In some aspects, the amount of such further materials is up to about 5 % by total weight of the flame retardant fiber-reinforced polypropylene composition (i.e. the pellets).

[0060] The (pellets of) flame retardant fiber-reinforced polypropylene composition according to the present disclosure may in some aspects comprise 10-40 % by total weight of the flame retardant fiber-reinforced polypropylene composition of fibers, and in particular aspects from 15-40 %, such as 20-35 %.

[0061] The fibers used in the composition of the disclosure in some aspects include, but are not limited to, glass fibers ( includin long glass fibers, short glass fibers, and chopped glass fibers), aramid fibers, basalt fibers (including continuous basalt fibers), wollastonite fibers, ceramic fibers, slag wool fibers, stone wool fibers, and processed mineral fibers from mineral wool, or any combination thereof. In certain aspects, the fibers used in the composition of the disclosure are glass fibers.

[0062] In certain aspects, the fibers (such as glass fibers) can have a diameter in the range of 5-50 μηι, and in further aspects the fibers have a diameter in the range of 10-30 μηι. such as 15-25 urn. A thinner fiber generally leads to higher aspect ratio (length over diameter ratio) of the fibers in the final product prepared from the fiber-reinforced composition, yet thinner fibers may be more difficult to manufacture and or handle.

[0063] In an aspect of the method according to the disclosure, glass fibers are used that originate from glass multifiber strands, also referred to as glass rovings. Such glass multifiber strand(s) or rovings may in some aspects comprise 500- 0000 glass filaments per strand, and in particular aspects 2000-5000 glass filaments per strand. The linear density of the glass multifiber strand may in some aspects be from 1000-5000 tex, corresponding to 1000-5000 grams per 1000 meter. The linear density may be from 1000-3000 tex. Usually, the glass fibers are circular in cross section meaning the thickness as defined above would mean diameter. Rovings are generally available and well known to the skilled person. Examples of suitable commercially available rovings are the Advantex products designated for example as SE4220. SE4230 or SE4535 and available from Binani 3B Fiber Glass company, available as 1200 or 2400 tex, or TUFRov 4575, TUFRov 4588 available from PPG Fiber Glass. In particular aspects rovings are used having a linear density of 3000 tex. These commercially available rovings contain glass fibers having a small amount of sizing composition applied thereon; typically the amount of such sizing is less than 2 % by total weight of the fibers.

[0064] The pellets of the composition according to the present disclosure may in some aspects have a length of 5-40 mm. such as 8-20 mm. and in particular aspects 10-18 mm. The skilled person will understand that pellets may be substantially cylindrical with a circular cross section, yet other cross sectional shapes, like for example oval or (rounded) square are also possible and fall within the scope of the disclosure.

[0065] T he fibers (such as glass fibers) can have an average length, which is

approximately the same as the length of the pellets. Hence, the average length of the fibers can in some aspects be in the range of 5-40 mm, such as in the range of 8-20 mm, and in speci fically 10-18 mm More in particular, in the pellets, the fibers generally extend in the longitudinal direction as a result of which they lie substantially in parallel to one another. Typically, the fibers extending in a longitudinal direction have a length of between 95 % and 105 %, more in particular between 99 % and 101 % of the length of a pellet. In particular aspects the length of the fibers is substantially the same as the length of the pellet, yet due to some misalignment, twisting, or process inaccuracies the length may vary within the aforementioned range. In case of glass fibers, such glass fibers are generally classified as long glass fibers.

[0066] The pellets may have a core-sheath structure wherein the core comprises the fibers and the sheath is comprised of the polypropylene compound. In certain aspects the core is essentially free from polypropylene compound.

|0067| T he pellets can be manufactured with the wire-coating process as described in WO-A-2009/080821, the complete content of which is herewith incorporated by this reference.

100681 Another process to manufacture glass fiber-reinforced polypropylene materials is based on what is known as a pultrusion process. In such a process continuous glass multifiber strands are pulled through a molten resin in such a manner that the individual filaments are fully dispersed into the resin. Examples of such processes are disclosed in EP-A-1 364 760, NL-A-1 010 646 and WOA-2008/089963, the entire contents of which are incorporated herein by this reference in their entireties.

100691 One difference between pellets obtained by the wire-coating process and pellets obtained by the pultrusion process is that the glass fibers obtained by the wire-coating process are not dispersed in the polypropylene. This dispersion will generally take place once the pellets are molded into finished or semi-finished parts in dow nstream conversion processes. A further difference betw een the pultrusion process and the wire-coating is that the pultrusion process can only run at a relatively low speed, such as in the order of 30 meters per minute ( m min). To the contrary, the wire coating process can run at line speeds of 100 m/min or more, or even 300 m/min or more.

100701 The polypropylene composition may in some aspects comprise an impregnating agent. The amount of impregnating agent may vary and is in some aspects 0.5-7 % by total weight of the flame retardant fiber-reinforced polypropylene composition. The amount of impregnating agent may also be expressed relative to the weight of the fibers. The amount of impregnating agent may thus be 5-15 % by total weight of the fibers, such as 7-15 %.

[0071] The presence of an impregnating agent allows a good dispersion of [he fibers within the polypropylene composition during downstream conversion processes, such as for example injection molding. In addition to that the impregnating agent also couples the fibers to each other and to the sheath to a certain extent.

[0072] It may be desirable in some aspects to use an impregnating agent as described in WO-A-2009/080821. The impregnating agent is non- volatile, has a melting point of at least about 20 °C below the melting point of the polypropylene compound sheath and has a viscosity of 2.5-100 centistokes (cS) at application temperature.

[0073] The viscosity of the impregnating agent in some aspects may be 100 cS or less, such as 75 cS or less, or even 25 cS or l ess at application temperature. The viscosity of the impregnating agent can be 2.5 cS or more, such 5 cS or more, and even 7 cS or more at the application temperature. An impregnating agent having a viscosity of more than 100 cS is difficult to apply to a continuous strand of glass fibers. Low viscosity may be preferable to facilitate good wetting performance of the glass fibers, but an impregnating agent having a viscosity of less than 2.5 cS is di ficult to handle, e.g., the amount to be appl ied is difficult to control.

[0074] The melting temperature of the impregnating agent can be at least about 20 °C, such as at least 25 °C or at least 30 °C below the melting point of the polypropylene composition sheath. The application temperature of the impregnating agent is suitably selected such that the desired viscosity range is obtained.

[0075] The amount of impregnating agent that is applied depends inter alia on the thermoplastic polymer used for the sheath, the amount of fibers, the size (diameter) of the fibers, and on the type of sizing that is on the surface of the fibers. According to the disclosure, the amount of impregnating agent applied to the fibers is in some aspects 0.5 % or more by total weight of the fibers (including the sizing composition), such as 2 % or more, 4 % or more, or 6 % or more. The amount of impregnating agent is typically 20 % or less by total weight of the fibers (including the sizing composition), such as 18 % or less, 15 % or less, or 12 % or less. In general, a higher amount of fibers may in some aspects necessitate a higher amount of impregnating agent. A certain minimum amount of impregnating agent is desired to assist homogeneous dispersion of fibers in the thermoplastic polymer matrix during molding. An excess of impregnating agent may result in decrease of mechanical properties of the molded articles. [ΘΘ76] Suitable examples of impregnating agents for use in combination with polypropylene as the material for the sheath may comprise highly branched poly(a-olefms), such as polyethylene waxes, modified low molecular weight poK propylenes, mineral oils, such as, paraffin or silicon and any mixtures of these compounds. The impregnating agent may in some aspects comprise a highly branched poly(a-olefm) and, specifically, the impregnating agent may be a highly branched polyethylene wax. The wax may optionally be mixed with a hydrocarbon oil or wax like a paraffin oil to reach the desired viscosity.

WO-A-2009/080281 discloses as an exemplary impregnating agent a blend of 30 wt.% of V bar 260 (hyper branched polymer supplied by Baker Petrolite) and 70 wt.% of Paralux oil (paraffin, supplied by Chevron). The term non-volatile means that the impregnating agent does not evaporate under the application and processing conditions applied. In the context of the present application, "substantially solvent-free" means that the impregnating agent contains 10 % or less by mass of solvent, such as 5 % or less by mass of solv ent. In particular aspects the impregnating agent is free of any solvent. The impregnating agent may further be mixed with other additives known in the art.

[0077] In particular aspects, the impregnating agent comprises 70 % or more by total weight of the impregnating agent of microciy stalline wax. In that respect it is to be understood that the mi crocry stalline wax may be a single microciy stalline wax or a blend of several microcry stalline waxes. Microcty stalline waxes are known materials. In general a microcry stalline wax is a refined mixture of solid saturated aliphatic hydrocarbons, and produced by de-oilin certain fractions from the petroleum refining process. Microciystalline waxes differ from refined paraffin wax in that the molecular structure is more branched and the hydrocarbon chains are longer (higher molecular weight). As a result the crystal structure of microciystalline wax is much finer than paraffin wax, which directly impacts many of the mechanical properties of such materials. Microciy stalline waxes are tougher, more flexible and generally higher in melting point compared to paraffin wax. The fine crystalline structure also enables microciystalline wax to bind solvents or oil and thus prevents the sweating out of compositions. Microcry stalline wax may be used to modify the crystalline properties of paraffin wax. Microciystalline waxes are also very different from so-called iso-polymers. First of all, microciystalline waxes are petroleum based whereas iso-polymers are polv-α -olefins. Secondly iso-polymers have a very high degree of branching of above 95 %, whereas the amount of branching for microciystalline waxes generally lies in the range of 40-80 wt.%. Finally, the melting point of iso-polymers generally is relatively low compared to the melting temperature of mi crocry stalline waxes. All in all. microcrystalline waxes form a distinct class of materials not to be confused either by paraffin or by iso-polymers.

[0078] The remaining 30 % or less by total weight of the impregnating agent may- comprise a natural or synthetic wax or an iso-polymer. Typical natural waxes are animal waxes such as bees wax, lanolin and tallow, vegetable waxes such as camauba, candelilla, soy, mineral waxes such as paraffin, ceres i and montan. Typical synthetic waxes include ethylenic polymers such as polyethylene wax or polyol ether-ester waxes, chlorinated naphthalenes and Fisher-Tropsch derived waxes. A typical example of an iso-polymer. or hyper-branched polymer, is Vybar 260 mentioned above. In an aspect, the remaining 30 % or less by total weight of the impregnating agent comprises or consists of one or more selected from a highly branched poly-α -olefin (such as a polyethylene wax) and paraffin. In a further aspect, the impregnating agent comprises at least 80 % or more by total weight of the impregnating agent of microcrystalline was, such as 90 % or more, or 95 % or more, or 99 % or more. In a particular aspect the impregnating agent substantially consists of

microcrystalline wax. The term "substantially consists of is to be interpreted such that the impregnating agent comprises 99.9 % or more by total weight of the impregnating agent of microcrystalline wax. In an aspect, the impregnating agent is free of paraffin.

[0079] The skilled person will understand that the core of the pellet comprising the fibers and the impregnating agent will only be surrounded by the polypropy lene compound sheath in the longitudinal direction. Hence, the core of the pellet is exposed to the surrounding at the two cutting planes, or cross sectional surfaces corresponding to the positions where the pellet was cut. It is for this reason that upon insufficient coupling of the fibers to the sheath the fibers may separate from the pellet.

100801 The flame retardant fiber-reinforced poK propylene composition may in some aspects exhibit a UL-94 flame retardaticy rating of V0 at 3.2 mm thickness, or a V0 rating at 2.0 mm thickness, or a V0 rating at 1.6 mm thickness. The flame retardant fiber-reinforced polypropylene composition may in certain aspects pass the UL-94 5V rating at 3.2 mm thickness, or it may pass the UL-94 5V rating at 2.0 mm thickness, tested on bars.

[0081] The flame retardant fiber-reinforced polypropylene composition may exhibit a Glow Wire Fiammability Index as measured according to IEC-60695-2-12 of 725 °C or more at 0.8 mm thickness. [0082J The flame retardant fiber-reinforced polypropylene composition in certain aspects exhibits a comparative tracking index measured according to International

Electrotechnical Commission standard IEC-60112/3^ld of 600 volts (V) or more.

[0083] In order to get a UL-94 V0 rating at 1.6 mm thickness, the amount of flame retardant material should in some aspects be selected according to the following equation (1):

FR≥ 0.5 x GF + 5 (1)

[0084] wherein FR is the amount of flame retardant composition in % by total weight of the flame retardant fiber-reinforced polypropylene composition, and GF is the amount of fibers in % by total weight of the flame retardant fiber-reinforced polypropylene composition. The amount of fibers may in some aspects be 15 % or more by total weight of the flame retardant fiber-reinforced polypropylene composition, such as 20-40 %. ii) Composition with flame retardant free fiber-reinforced polypropylene composition

[0085] In a second option, the component for a medical application is obtainable by- using a composition (such as a molding composition) that comprises:

[0086] a) pellets of a fiber-reinforced polypropylene composition having a core containing fibers and a sheath of a first polypropylene compound surrounding the core, wherein the fiber-reinforced polypropylene composition comprises 10-70 % by total weight of the fiber-reinforced polypropylene composition of fibers and 30-90 % by total weight of the fiber-reinforced polypropylene composition of polypropylene compound, the fiber- reinforced polypropylene composition not containing a flame retardant composition, and

[0087] b) a fiame retardant polypropylene dilution composition comprising a second polypropylene compound containing a fiame retardant composition comprising a mixture of an organo-phosphorous compound, an organic phosphoric acid compound, zinc oxide, and optionally a nitrogen-containing compound.

[0088] With respect to the type of fibers, the type of first polypropylene compound, the amount and type of impregnating agent in the pellets of the fiber-reinforced polypropylene composition, the description of the first option of the disclosure equally applies, except for the fiame retardant composition which is excluded from the pellets according to the second option of the disclosure. Similarly, the flame retardancy, and the mechanical properties as described for the first option equally apply to the second option of the disclosure.

[0089] The fiber-reinforced polypropylene composition in the composition of the disclosure and not containing a flame retarding composition, i.e. option ii)a), comprises in some aspects 15-70 % by total weight of the fiber-reinforced polypropylene composition of fibers, such as 20-70 %, or 30-65 %.

[0090] The flame retardant polypropylene dilution composition may in some aspects be in the form of pellets based on a homogeneous mixture of the flame retardant composition and the second polypropylene compound.

[0091] The mixture of organo-phosphorous compound, organic phosphoric acid compound, zinc oxide, and optionally nitrogen-containing compound is as described herein above for the first option of the disclosure.

[0092] In certain aspects, the flame retardant dilution composition consists of pellets according to first option of the disclosure.

[0093] T he polypropylene of the second polypropylene compound may be the same or different as the polypropylene of the first poK propylene compound and in particular aspects is the same.

[0094] The advantage of the second option of the disclosure is that it gives more production flexibility in that the amount of fibers as well as the amount of fl ame retardant in the final component manufactured from the composition can be selected without a change in the fiber-reinforced composition. In other words, standard and/or existing fiber-reinforced polypropylene grades can be used.

[0095] In a further aspect, the composition comprises a third polypropylene compound not containing a flame retardant composition.

[0096] T he poK propylene of the third poK propylene compound may be the same or different as the first or second polypropylene. By using a third polypropylene compound a converter has the freedom in designing an end product wherein the mechanical properties, in terms of amount of fibers, and the flame retardancy in terms of amount of flame retardant composition can be selected using more or less standard components. [ΘΘ97] The third polypropylene compound may in some aspects be in the form of pellets, which can be a commercially available polypropylene material.

Hi) Composition with flame retardant fiber-reinforced polypropylene composition

[0098] In a third option, the component for a medical application is obtainable by using a composition (such as a molding composition) that comprises:

[0099] a) pellets of a flame retardant fiber-reinforced polypropylene composition having a core containing fibers and a sheath of a polypropylene compound comprising a flame retardant composition and surrounding the core, w herein the flame retardant composition comprises a mixture of an organ o-phosphorous compound, an organic phosphoric acid compound, zinc oxide, and optionally a nitrogen-containing compound, and

[00100] b) a flame retardant polypropylene dilution composition comprising a second polypropy lene compound containing a flame retardant composition comprising a mixture of an organophosphorous compound, an organic phosphoric acid compound, zinc oxide, and optionally a nitrogen-containing compound.

1001011 In accordance with this option, the ( pel lets of the) flame retardant fi ber- reinforced polypropylene composition comprises in some aspects: 35-80 % by total weight of the composition of polypropylene compound, 10-40 % by total weight of the composition of fibers; and/or 10-35 % by total weight of the composition of a flame retardant composition.

[00102] In accordance with this third option, the amount of flame retardant is the same as in the first option. Hence, the amount of flame retardant composition is 10-35 % by total weight of the flame retardant fiber-reinforced polypropylene composition. Higher amounts, such as from 20-35 % may be used for applications that need to be compliant with a

UL-94 5 V rating. For UL-94 V0 ratings lower amounts may suffice, depending also on the amount of glass fibers as explained herein, and on the amount of pellets of the dilution polypropylene composition.

[00103] The (pellets of) flame retardant fiber-reinforced polypropylene composition according to option iii), may in some aspects comprise 1 0-40 % by total weight of the flame retardant fiber-reinforced polypropylene composition of fibers, such as 15-40 %, or 20-35 %. |001041 With respect to the type of fibers, the type of polypropylene compound and the amount and type of impregnating agent in the pellets of the flame retardant fiber-reinforced polypropylene compositi on, the description of the first and second opti ons equally applies. Similarly, the flame retardancy, and the mechanical properties as described for the first and second options equally apply to the third option.

[00105] The mixture of organo-phosphorous compound, organic phosphoric acid compound, zinc oxide, and optionally a nitrogen-containing compound is as described herein above for the first and second option of the disclosure.

[00106] The term "article" as used in this application is meant to include both complete components, as well as portions of components for various application including medical applications. The article for a medical application can have a wide variety of applications, particularly those requiring sanitation and cleaning with medical grade cleaners and processes. The components can be manufactured by any suitable downstream conversion process, including foaming, molding, thermoforming, extruding, and casting the pellets i) or compositions ii) or iii). Typical molding methods include injection molding, extrusion (including sheet extrusion and. or co-extrusion), rotational molding, blow moldin and thermoforming. Thus, the component may be in the form of a foamed article, a molded article, a thermoformed article, an extruded film, an extruded sheet, a layer of a multilayer article (e.g. a cap layer), a substrate for a coated article, or a substrate for a metallized article. Suitably, the component can be in the form of a panel, a laminate, a multilayer, a foam, or a honeycomb.

[00107] All references cited herein are hereby completely incorporated by reference to the same extent as if each reference were individually and specifically indicated to be incorporated by reference and were set forth in its entirety herein.

[00108] The use of the terms "a" and "an" and "the" and similar referents in the context of describing the disclosure (especially in the context of the claims) are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly- contradicted by context. The terms "comprising", "having", "including" and "containing" are to be construed as open-ended terms (i.e. , meaning "including, but not limited to") unless otherwise noted. Recitation of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range, unless otherwise indicated herein, and each separate value is incorporated into the specification as if it were individually recited herein. The use of any and all examples, or exemplar}^' language (e.g. , "such as") provided herein, is intended merely to better illuminate the disclosure and does not pose a limitation on the scope of the disclosure unless otherwise claimed. No language in the specification should be construed as indicating any non-claimed element as essential to the practice of the disclosure. For the purpose of the description and of the appended claims, except where otherwise indicated, all numbers expressing amounts, quantities, percentages, and so forth, are to be understood as being modified in all instances by the term "about". Also, all ranges include any combination of the maximum and minimum points disclosed and include and intermediate ranges therein, which may or may not be specifically enumerated herein.

|001091 Preferred aspects of this disclosure are described herein. Variation of those preferred aspects may become apparent to those of ordinary skill in the art upon reading the foregoing description. The inventors expect skilled artisans to employ such variations as appropriate, and the inventors intend for the disclosure to be practiced otherwise than as specifically described herein. Accordingly, this disclosure includes all modifications and equivalents of the subject-matter recited in the claims appended hereto as permitted by- applicable law. Moreover, any combination of the above-described elements in all possible variations thereof is encompassed by the disclosure unless otherwise indicated herein or otherwise clearly contradicted by context. The claims are to be construed to include alternative aspects to the extent permitted by the prior art.

[00110] For the purpose of clarity and a concise description features are described herein as part of the same or separate aspects, however, it will be appreciated that the scope of the disclosure may include aspects havin combinations of all or some of the features described.

[00111] While t pical aspects have been set forth for the purpose of illustration, the foregoing descriptions should not be deemed to be a limitation on the scope of the disclosure. Accordingly, various modifications, adaptations, and alternatives can occur to one skilled in the art without departing from the spirit and scope of the present disclosure.

[00112] The present disclosure can be understood more readily by reference to the following detailed description, examples, drawings, and claims, and their previous and following description. However, before the present compositions, articles, devices, systems, and or methods are disclosed and described, it is to be understood that this disclosure is not limited to the specific aspects of compositions, articles, devices, systems, and. or methods disclosed unless otherwise specified, as such can, of course, vary. It is also to be understood that the terminology used herein is for the purpose of describing particular aspects of the disclosure only and is not intended to be limiting.

|00113] The following description of the disclosure is also provided as an enabling teaching of the disclosure in its best, currently known aspect. To this end, those of ordinary skill in the relevant art will recogni/e and appreciate that changes and modifications can be made to the various aspects of the disclosure described herein, while still obtaining the beneficial results of the present disclosure. It will also be apparent that some of the desired benefits of the present disclosure can be obtained by selecting some of the features of the present disclosure without utilizing other features. Accordingly, those of ordinary skill in the relevant art will recogni/e that many modifications and adaptations to the present disclosure are possible and can even be desirable in certain circumstances and are thus also a part of the present disclosure. Thus, the following description is provided as illustrative of the principles of the present disclosure and not in limitation thereof.

[00114] Various combinations of elements of this disclosure are encompassed by this disclosure, e.g. combinations of elements from dependent claims that depend upon the same independent claim.

[00115] Moreover, it is to be understood that unless otherwise expressly stated, it is in no way intended that any method set forth herein be construed as requiring that its steps be performed in a speci fic order. Accordingly, where a method claim does not actually recite an order to be followed by its steps or it is not otherwise specifically stated in the claims or descriptions that the steps are to be limited to a speci fic order, it is no way intended that an order be inferred, in any respect. This holds for any possible non-express basis for interpretation, including: matters of logic with respect to arrangement of steps or operational flow; plain meaning derived from grammatical organization or punctuation, and the number or type of aspects described in the specification.

|00116] Any publications mentioned herein are incorporated herein by reference to disclose and describe the methods and or materials in connection with which the publications are cited. [00117] It is also to be understood that the terminology used herein is for the purpose of describing particular aspects only and is not intended to be limiting. As used in the specification and in the claims, the term "comprising" may include the aspects or aspects "consisting of and "consisting essentially of." Unless defined otherw ise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure belongs. In this specification and in the claims which follow, reference will be made to a number of terms which shall be defined herein.

[00118] As used in the specification and the appended claims, the singular forms "a," "an" and "the" include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to "a glass fiber" includes mixtures of two or more such glass fibers.

[00119] Ranges can be expressed herein as from one value (first value) to another value (second value). When such a range is expressed, the range includes in some aspects one or both of the first value and the second value. Similarly, when values are expressed as approximations, by use of the antecedent "about," it will be understood that the particular value forms another aspect. It will be further understood that the endpoints of each of the ranges are significant both in relation to the other endpoint. and independently of the other endpoint. It is also understood that there are a number of values disclosed herein, and that each value is also herein disclosed as "about" that particular value in addition to the value itself. For example, if the value "10" is disclosed, then "about 10" is also disclosed. It is also understood that each unit falling within a range between two particular units are also disclosed. For example, if 10 and 15 are disclosed, then 11, 12, 13, and 14 are also disclosed.

[00120] As used herein, the terms "about" and "at or about" mean that the amount or value in question can be the designated value, approximately the designated value, or about the same as the designated value. It is generally understood, as used herein, that it is the nominal value indicated ±1 0% variation unless otherwise indicated or inferred. The term is intended to convey that similar values promote equivalent results or effects recited in the claims. That is, it is understood that amounts, sizes, formulations, parameters, and other quantities and characteristics are not and need not be exact, but can be approximate and/or larger or smaller, as desired, reflecting tolerances, conversion factors, rounding off, measurement error and the like, and other factors known to those of skill in the art. In general, an amount, size, formulation, parameter or other quantity or characteristic is "about" or "approximate" whether or not expressly stated to be such, it is understood that where "about" is used before a quantitative value, the parameter also includes the specific quantitative value itself, unless specifically stated otherwise.

[00121] As used herein, the terms "optional" or "optionally" mean that the subsequently described event, condition, component, or circumstance may or may not occur, and that the description includes instances where the event or circumstance occurs and instances where it does not.

[00122] As used herein, the term or phrase "effective," "effective amount," or "conditions effective to" refers to such amount or condition that is capable of performing the function or property for which an effective amount is expressed. As will be pointed out below, the exact amount or particular condition required may vary from one aspect or aspect to another, depending on recognized variables such as the materials employed and the processing conditions observed. Thus, it is not always possible to specify an exact "effective amount" or "condition effective to" for each aspect or aspect encompassed by the present disclosure. However, it should be understood that an appropriate effective amount or condition effective to achieve a desired results will be readily determined by one of ordinary skill in the art using only routine experimentation.

[00123] Disclosed are the components to be used to prepare disclosed compositions of the disclosure as well as the compositions themselves to be used within methods disclosed herein. These and other materials are disclosed herein, and it is understood that when combinations, subsets, interactions, groups, etc. of these materials are disclosed that while specific reference of each various individual and collective combinations and permutation cannot be explicitly disclosed, each is specifically contemplated and described herein. This concept applies to all aspects of this application including, but not limited to, steps in methods of making and using the compositions of the disclosure. Thus, if there are a variety of additional steps that can be performed it is understood that each of these additional steps can be performed with any specific aspect or combination of aspects of the methods of the disclosure.

[00124] References in the specification and concluding claims to parts by weight, of a particular component in a composition or article, denotes the weight relationship between the element or component and any other elements or components in the composition or article for which a part by weight is expressed. Thus, in a composition containing 2 parts by weight of component X and 5 parts by weight component Y, X and Y are present at a weight ratio of 2:5, and are present in such ratio regardless of whether additional components are contained in the compound.

[00125] A weight percent (wt. %) of a component, unless specifically stated to the contrary, is based on the total weight of the formulation or composition in which the component is included. For exampl e if a particular element or component in a composition or article is said to have 8% weight, it is understood that this percentage is relation to a total compositional percentage of 100%.

[00126] Each of the component starting materials disclosed herein are either

commercially available and/or the methods for the production thereof are known to those of skill in the art.

[00127 j It will be apparent to those skilled in the art that various modi fications and variations can be made in the present disclosure without departing from the scope or spirit of the disclosure. Other aspects of the disclosure will be apparent to those skilled in the art from consideration of the specification and practice of the disclosure discl osed herein. It is intended that the specification and examples be considered as exemplary only, with a true scope and spirit of the disclosure being indicated by the following claims.

Claims

What is claimed is:

An enclosure formed from a thermoplastic composition comprising:

a) a homopolymer component comprising polypropylene, a copolymer component comprising polypropylene, or a combination thereof;

b) an impact modifier;

c) a flame retardant component; and

d) a fiber reinforcement component,

wherein the enclosure is configured to house an electrical component.

The enclosure of claim 1, further comprising one or more additives selected from the group consisting of a coupling agent, heat stabilizer, flow modifier, and colorant.

The enclosure of any one of claims 1-2, wherein the enclosure is chemically resistant to a medical grade cleaner.

The enclosure of any one of claims 1-3, wherein the homopolymer component comprises one or more of a low flow grade polypropylene and a high flow grade polypropylene.

The enclosure of any one of claims 1-4, wherein the copolymer component comprises one or more of a low flow grade polypropylene and a high flow grade polypropylene.

The enclosure of any one of claims 1-5, comprising from 20 to 90 weight percent of the fiber reinforcement component relative to the weight of the thermoplastic composition.

The enclosure of any one of claims 1-6, wherein the thermoplastic composition has a melt flow rate (MFR) of between 14 and 8 g/10 minutes when measured at a temperature of 210 °C and under 5 kg load.

8. The enclosure of any one of claims 1 -7, wherein the fiber reinforcement component comprises a glass fiber.

9. The enclosure of claim 8, wherein the fiber reinforcement component comprises a long glass fiber having a length after extrusion or molding of from about 2 mm to about 15 mm.

10. The enclosure of claim 8, wherein the fiber reinforcement component comprises short glass fibers having a length after extrusion or molding of from about 0.1 mm to about 0.2 mm.

11. An article for a medical application, the article comprising: i) a composition comprising pellets of a flame retardant fiber-reinforced polypropylene composition having a core comprising fibers and a sheath of a polypropylene compound comprising a flame retardant composition and surrounding the core, wherein the flame retardant composition comprises a mixture of an organo phosphorous compound, an organic phosphoric acid compound and zinc oxide; ii) a composition comprising: a) pellets of a fiber-reinforced polypropylene composition having a core comprising fibers and a sheath of a first polypropylene compound surrounding the core, wherein the fiber-reinforced polypropylene composition comprises 10-70 % by total weight of the fiber-reinforced polypropylene composition of fibers and 30-90 % by total weight of the fiber-reinforced polypropylene composition of polypropylene compound, the fiber-reinforced polypropylene composition not containing a flame retardant composition, and b) a flame retardant polypropylene dilution composition comprising a second polypropylene compound containing a flame retardant composition comprising a mixture of an organo phosphorous compound, an organic phosphoric acid compound and zinc oxide; or iii) a composition comprising: a) pellets of a flame retardant fiber-reinforced polypropylene composition having a core comprising fibers and a sheath of a polypropylene compound comprising a flame retardant composition and surrounding the core, wherein the flame retardant composition comprises a mixture of an organo phosphorous compound, an organic phosphoric acid compound and zinc oxide, and b) a flame retardant polypropylene dilution composition comprising a second polypropylene compound containing a flame retardant composition comprising a mixture of an organo phosphorous compound, an organic phosphoric acid compound and zinc oxide.

12. The article of claim 1 1, wherein the pellets of a flame retardant fiber-reinforced

polypropylene composition i) comprise:

25-80 % by total weight of the composition of polypropylene compound;

10-40 % by total weight of the composition of fibers, or

10-35 % by total weight of the composition of a flame retardant composition.

13. The article of claim 1 1 or 12, wherein the pellets of fiber-reinforced polypropylene composition ii)a) comprise 15-70 % by total weight of the fiber-reinforced polypropylene composition of fibers.

14. The article of any one of claims 11 -13, wherein the pellets of a flame retardant fiber- reinforced polypropylene composition iii) comprise:

35-80 % by total weight of the composition of polypropylene compound;

10 40 % by total weight of the composition of fibers; or

10-35 % by total weight of the composition of a flame retardant composition.

15. The article of any one of claims 11 -14, wherein the fibers are selected from the group consisting of glass fibers, basalt fibers, wollastonite fibers, ceramic fibers, slag wool fibers, stone wool fibers, processed mineral fibers from mineral wool, and a combination thereof.

16. The article of any one of claims 11 -15, wherein the article is an enclosure.

17. The article of any one of claims 11 -16, wherein the article is configured to house an electrical component.

18. The article of any one of claims 11 -17, wherein the article is chemically resistant to a medical grade cleaner.