Thermoplastic articles and processes for making the same using an improved masterbatch

A process for making a shaped article, comprising the steps of:

• a) providing as separate materials a first material that includes a first polyolefin, and a second material including an admixture of:
• (i) from about 45 to 85 wt. % of the total admixture of at least one particulated mineral filler;
• and
• (ii) from about 15 to 55 wt. % of the total admixture of at least a second polyolefin wherein the second polyolefin comprises a polyolefin plastomer that includes a thermoplastic having a primary monomer of ethylene, a comonomer selected from the group consisting of 1-butene, 1-hexene, and 1-octene, and is characterized by a melt index greater than 150 g/10 min at 190° C./2.16 kg, as measured per ISO 1133 (condition D);
• b) applying a shear force to the first and second materials, while the materials are at an elevated temperature for blending the materials to form a molten blend;
• c) shaping the molten blend;
• and
• d) solidifying the molten blend;
• wherein
• the step of applying a shear force occurs while the first and second materials advance along a screw within a screw and barrel assembly;
• the process is substantially free of a step of compounding together the first and second materials prior to introducing the first and second materials to the screw and barrel assembly;
• the first polyolefin of the first material comprises a thermoplastic polyolefin;
• the polyolefin plastomer includes a polymer made with a metallocene catalyst;
• the second material further comprises a propylene-ethylene copolymer characterized by a melt index greater than 10 g/10 min at 230° C./2.16 kg as measured per ISO 1133 (condition M) and a flexural modulus of less than 100 MPa, as measured per ASTM D-790A;
• and
• the thermoplastic polyolefin of the first material includes a polypropylene impact copolymer characterized by a melt flow rate of less than 70 g/10 min (ISO 1133 condition M at 230° C., 2.16 kg), containing greater than 8 wt % (of the first material) of ethylene, having greater than about 40% crystallinity, or any combination thereof.

A process for making a shaped article, comprising the steps of:

• a) providing as separate materials:
• a first material that includes a polypropylene impact copolymer characterized by a melt flow rate of less than 70 g/10 min (ISO 1133 condition M at 230° C., 2.16 kg), containing greater than 8 wt % (of the first material) of ethylene, having greater than 40% crystallinity, or any combination thereof;
• and
• and a second material including an admixture of:
• (i) from 45 to 85 wt. % of the total admixture of at least one particulated mineral filler;
• and
• (ii) from 15 to 55 wt. % of the total admixture of at least a second polyolefin wherein the second polyolefin comprises a polyolefin plastomer that includes a thermoplastic having a primary monomer of ethylene, a comonomer selected from the group consisting of 1-butene, 1-hexene, and 1-octene, and is characterized by a melt index greater than 150 g/10 min at 190° C./2.16 kg, as measured per ISO 1133 (condition D);
• b) applying a shear force to the first and second materials, while the materials are at an elevated temperature for blending the materials to form a molten blend;
• c) shaping the molten blend;
• and
• d) solidifying the molten blend;
• wherein
• the step of applying a shear force occurs while the first and second materials advance along a screw within a screw and barrel assembly, and
• the process is substantially free of a step of compounding together the first and second materials prior to introducing the first and second materials to the screw and barrel assembly.