POLYOLEFIN COMPOSITIONS FOR BUILDING MATERIALS

Abstract

A polyolefin composition includes a polyolefin substrate having incorporated therein a nucleating agent and a filler, wherein the composition exhibits an impact strength of >35 in-lb measured according to ASTM D4226, and a coefficient of linear thermal expansion of <4.510E-05 in/in/ft measured according to ASTM D696. The polyolefin composition may further include one or more of an ultraviolet light absorber, a hindered amine light stabilizer, an antioxidant, a colorant, a flame retardant, and an antimicrobial compound. The polyolefin compositions may be useful for construction articles for outdoor use, for instance house siding, cladding, soffit or roofing.

Claims

1. A polyolefin composition comprising a polyolefin substrate having incorporated therein a nucleating agent and a filler, wherein the composition exhibits an impact strength of >35 in-lb measured according to ASTM D4226, and a coefficient of linear thermal expansion of <4.510E-05 in/in/ft measured according to ASTM D696.

2. The polyolefin composition of claim 1, wherein the polyolefin substrate further comprises an additive selected from the group consisting of: an ultraviolet light absorber, a hindered amine light stabilizer, an antioxidant, a colorant, a flame retardant, and an antimicrobial compound.

3. The polyolefin composition of claim 1, wherein the polyolefin substrate comprises polyethylene, polypropylene, an ethylene/propylene copolymer, or a mixture of any two or more thereof.

4. The polyolefin composition of claim 1, wherein the nucleating agent comprises sodium benzoate, 2,2-methylene-bis(4,6-di-tert-butylphenyl)phosphate, zinc glycerolate, calcium salt of 1,2-dicarboxylic acid cyclohexane, aromatic trisamide compounds, cis-endo-bicyclo-[2.2.1]-heptane-2,3-dicarboxylic acid disodium salt, aluminum hydroxy-bis[4-(tert-butyl)benzoate], 1,3:2,4-bis-(3,4-dimethylbenzylidene)sorbitol 1,3:2,4-bis(4-methylbenzylidene)sorbitol, 1,3:2,4-bis(3,4-dimethylbenzylidene)sorbitol, or a mixture of any two or more thereof.

5. The polyolefin composition of claim 1, wherein the one or more fillers comprise a natural fiber or an inorganic filler.

6. The polyolefin composition of claim 5 comprising the inorganic filler, wherein the inorganic filler comprises one or more of dolomite, silica, calcium carbonate, magnesium hydroxide, zinc borate, talc, vermiculite, diatomite, perlite, wallastonite, fly ash, kaolin clay, or mica or titanium dioxides.

7. The polyolefin composition of claim 5 comprising the inorganic filler, and the inorganic filler comprises one or more of calcium carbonate, magnesium hydroxide, talc, wollastonite, or fly ash.

8. The polyolefin composition of claim 1, wherein the nucleating agent comprises an aromatic trisamide compound.

9. The polyolefin composition of claim 1, wherein the filler comprises calcium carbonate.

10. The polyolefin composition of claim 1, wherein the nucleating agent comprises from about 12 ppm to about 500 ppm based on the weight of the polyolefin substrate.

11. The polyolefin composition of claim 1, wherein the filler comprises from about 15 wt % to about 40 wt %, based on the weight of the polyolefin substrate.

12. The polyolefin composition of claim 2: wherein: the ultraviolet light absorber is selected from the group consisting of 5-chloro-2-(3-t-butyl-2-hydroxy-5-methylphenyl)-2H-benzotriazole, 2-(3,5-bis--cumyl-2-hydroxyphenyl)-2H-benzotriazole, 4,6-diphenyl-2-(4-hexyloxy-2-hydroxyphenyl)-s-triazine, 4,6-bis-(2,4-dimethylphenyl)-2-(2-hydroxy-4-octyloxyphenyl)-s-triazine, hexadecyl 3,5-di-tert-butyl-4-hydroxybenzoate, 2,4-di-tert-butylphenyl 3,5-di-tert-butyl-4-hydroxybenzoate, 4-octyloxy-2-hydroxybenzophenone, and mixture of any two or more thereof; the hindered amine light stabilizer is selected from the group consisting of (1) 1-cyclohexyloxy-2,2,6,6-tetramethyl-4-octadecylaminopiperidine; (2) bis(2,2,6,6-tetramethylpiperidin-4-yl) sebacate; (3) bis(1-acetoxy-2,2,6,6-tetramethylpiperidin-4-yl) sebacate; (4) bis(1,2,2,6,6-pentamethylpiperidin-4-yl) sebacate; (5) bis(1-cyclohexyloxy-2,2,6,6-tetramethylpiperidin-4-yl) sebacate; (6) bis(1-octyloxy-2,2,6,6-tetramethylpiperidin-4-yl) sebacate; (7) bis(1-acyl-2,2,6,6-tetramethylpiperidin-4-yl) sebacate; (8) bis(1,2,2,6,6-pentamethyl-4-piperidyl) n-butyl-3,5-di-tert-butyl-4-hydroxybenzylmalonate (9) 2,4-bis[(1-cyclohexyloxy-2,2,6,6-tetramethylpiperidin-4-yl)butylamino]-6-(2-hydroxyethylamino-s-triazine; (10) bis(1-cyclohexyloxy-2,2,6,6-tetramethylpiperidin-4-yl) adipate; (11) 2,4-bis[(1-cyclohexyloxy-2,2,6,6-piperidin-4-yl)butylamino]-6-chloro-s-triazine; (12) 1-(2-hydroxy-2-methylpropoxy)-4-hydroxy-2,2,6,6-tetramethylpiperidine; (13) 1-(2-hydroxy-2-methylpropoxy)-4-oxo-2,2,6,6-tetramethylpiperidine; (14) 1-(2-hydroxy-2-methylpropoxy)-4-octadecanoyloxy-2,2,6,6-tetramethylpiperidine; (15) bis(1-(2-hydroxy-2-methylpropoxy)-2,2,6,6-tetramethylpiperidin-4-yl) sebacate; (16) bis(1-(2-hydroxy-2-methylpropoxy)-2,2,6,6-tetramethylpiperidin-4-yl) adipate; (17) 2,4-bis{N-[1-(2-hydroxy-2-methylpropoxy)-2,2,6,6-tetramethylpiperidin-4-yl]-N-butylamino}-6-(2-hydroxyethylamino)-s-triazine; (18) 4-benzoyl-2,2,6,6-tetramethylpiperidine; (19) di-(1,2,2,6,6-pentamethylpiperidin-4-yl) p-methoxybenzylidenemalonate; (20) 2,2,6,6-tetramethylpiperidin-4-yl octadecanoate; (21) bis(1-octyloxy-2,2,6,6-tetramethylpiperidyl) succinate; (22) 1,2,2,6,6-pentamethyl-4-aminopiperidine; (23) 2-undecyl-7,7,9,9-tetramethyl-1-oxa-3,8-diaza-4-oxo-spiro[4,5]decane; (24) tris(2,2,6,6-tetramethyl-4-piperidyl) nitrilotriacetate; (25) tris-(2-hydroxy-3-(amino-(2,2,6,6-tetramethylpiperidin-4-yl)propyl) nitrilotriacetate; (26) tetrakis(2,2,6,6-tetramethyl-4-piperidyl)-1,2,3,4-butane-tetracarboxylate; (27) tetrakis-(1,2,2,6,6-pentamethyl-4-piperidyl)-1,2,3,4-butane-tetracarboxylate; (28) 1,1-(1,2-ethanediyl)-bis-(3,3,5,5-tetramethylpiperazinone); (29) 3-n-octyl-7,7,9,9-tetramethyl-1,3,8-triazaspiro[4.5]decan-2,4-dione; (30) 8-acetyl-3-dodecyl-7,7,9,9-tetramethyl-1,3,8-triazaspiro[4.5]decane-2,4-dione; (31) 3-dodecyl-1-(2,2,6,6-tetramethyl-4-piperidyl)pyrrolidin-2,5-dione; (32) 3-dodecyl-1-(1,2,2,6,6-pentamethyl-4-piperidyl)pyrrolidine-2,5-dione; (33) N,N-bis-formyl-N,N-bis(2,2,6,6-tetramethyl-4-piperidyl)hexamethylenediamine; (33a) bis(1-undecanyloxy-2,2,6,6-tetramethylpiperidin-4-yl)carbonate; (34) reaction product of 2,4-bis[(1-cyclohexyloxy-2,2,6,6-piperidin-4-yl)butylamino]-6-chloro-s-triazine with N,N-bis(3-aminopropyl)ethylenediamine); (35) condensate of 1-(2-hydroxyethyl)-2,2,6,6-tetramethyl-4-hydroxypiperidine and succinic acid; (36) condensate of N,N-bis(2,2,6,6-tetramethyl-4-piperidyl)-hexamethylenediamine and 4-tert-octylamino-2,6-dichloro-1,3,5-triazine; (37) condensate of N,N-bis(2,2,6,6-tetramethyl-4-piperidyl)-hexamethylenediamine and 4-cyclohexylamino-2,6-dichloro-1,3,5-triazine; (38) condensate of N,N-bis-(2,2,6,6-tetramethyl-4-piperidyl)hexamethylenediamine and 4-morpholino-2,6-dichloro-1,3,5-triazine; (39) condensate of N,N-bis-(1,2,2,6,6-pentamethyl-4-piperidyl)hexamethylenediamine and 4-morpholino-2,6-dichloro-1,3,5-triazine; (40) condensate of 2-chloro-4,6-bis(4-n-butylamino-2,2,6,6-tetramethylpiperidyl)-1,3,5-triazine and 1,2-bis(3-aminopropylamino)ethane; (41) condensate of 2-chloro-4,6-di-(4-n-butylamino-1,2,2,6,6-pentamethylpiperidyl)-1,3,5-triazine and 1,2-bis-(3-aminopropylamino)ethane; (42) a reaction product of 7,7,9,9-tetramethyl-2-cycloundecyl-1-oxa-3,8-diaza-4-oxospiro-[4,5]decane and epichlorohydrin; (43) poly[methyl-(3-oxy-(2,2,6,6-tetramethylpiperidin-4-yl)propyl)]siloxane, CAS#182635-99-0; (44) reaction product of maleic acid anhydride-C.sub.18-C.sub.22--olefin-copolymer with 2,2,6,6-tetramethyl-4-aminopiperidine; (45) oligomeric condensate of 4,4-hexamethylenebis(amino-2,2,6,6-tetramethylpiperidine) and 2,4-dichloro-6-[(2,2,6,6-tetramethylpiperidin-4-yl)butylamino]-s-triazine end-capped with 2-chloro-4,6-bis(dibutylamino)-s-triazine; (46) oligomeric condensate of 4,4-hexamethylenebis(amino-1,2,2,6,6-pentamethylpiperidine) and 2,4-dichloro-6-[(1,2,2,6,6-pentamethylpiperidin-4-yl)butylamino]-s-triazine end-capped with 2-chloro-4,6-bis(dibutylamino)-s-triazine; (47) oligomeric condensate of 4,4-hexamethylenebis(amino-1-propoxy-2,2,6,6-tetramethylpiperidine) and 2,4-dichloro-6-[(1-propoxy-2,2,6,6-tetramethylpiperidin-4-yl)butylamino]-s-triazine end-capped with 2-chloro-4,6-bis(dibutylamino)-s-triazine; (48) oligomeric condensate of 4,4-hexamethylenebis(amino-1-acyloxy-2,2,6,6-tetramethylpiperidine) and 2,4-dichloro-6-[(1-acyloxy-2,2,6,6-tetramethylpiperidin-4-yl)butylamino]-s-triazine end-capped with 2-chloro-4,6-bis(dibutylamino)-s-triazine; (49) product obtained by reacting (a) with (b) where (a) is product obtained by reacting 1,2-bis(3-aminopropylamino)ethane with cyanuric chloride and (b) is (2,2,6,6-tetramethylpiperidin-4-yl)butylamine; and a mixture of any two or more thereof; the antioxidant is selected from the group consisting of organic phosphorus stabilizer/hindered phenolic antioxidant combinations, dialkylhydroxylamine stabilizers, organic phosphorus stabilizer/dialkylhydroxylamine stabilizer combinations, amine oxide stabilizers, organic phosphorus stabilizer/amine oxide stabilizer combinations, and a mixture of any two or more thereof; the colorant is selected from the group consisting organic pigments, inorganic pigments, and a mixture of any two or more thereof; and the flame retardants are selected from the group consisting of chlorinated flame retardants, brominated flame retardants, phosphorus based flame retardants, metal hydroxide compounds, melamine based compounds, antimony compounds, borate compounds, and a mixture of any two or more thereof.

13. The polyolefin composition of claim 2, wherein the hindered amine light stabilizer is selected from the group consisting of (2) bis(2,2,6,6-tetramethylpiperidin-4-yl) sebacate; (20) 2,2,6,6-tetramethylpiperidin-4-yl octadecanoate; (14) 1-(2-hydroxy-2-methyl-propoxy)-4-octadecanoyloxy-2,2,6,6-tetramethylpiperidine; (33) N,N-bis-formyl-N,N-bis(2,2,6,6-tetramethyl-4-piperidyl)hexamethylenediamine; (36) condensate of N,N-bis(2,2,6,6-tetramethyl-4-piperidyl)-hexamethylenediamine and 4-tert-octylamino-2,6-dichloro-1,3,5-triazine; (38) condensate of N,N-bis-(2,2,6,6-tetramethyl-4-piperidyl)-hexamethylenediamine and 4-morpholino-2,6-dichloro-1,3,5-triazine; (39) condensate of N,N-bis-(1,2,2,6,6-pentamethyl-4-piperidyl)hexamethylenediamine and 4-morpholino-2,6-dichloro-1,3,5-triazine; (44) reaction product of maleic acid anhydride-C.sub.18-C.sub.22--olefin-copolymer with 2,2,6,6-tetramethyl-4-aminopiperidine; (45) oligomeric compound condensate of 4,4-hexamethylenebis(amino-2,2,6,6-tetramethylpiperidine) and 2,4-dichloro-6-[(2,2,6,6-tetramethylpiperidin-4-yl)butylamino]-s-triazine end-capped with 2-chloro-4,6-bis(dibutylamino)-s-triazine; (47) oligomeric compound condensate of 4,4-hexamethylenebis(amino-1-propoxy-2,2,6,6-tetramethylpiperidine) and 2,4-dichloro-6-[(1-propoxy-2,2,6,6-tetramethylpiperidin-4-yl)butylamino]-s-triazine end-capped with 2-chloro-4,6-bis(dibutylamino)-s-triazine; and binary or ternary combinations thereof.

14. The polyolefin composition of claim 1, wherein the polyolefin substrate further has incorporated therein: a tris(2,4-di-tert-butylphenyl) phosphite/hindered phenolic antioxidant combination wherein the hindered phenolic antioxidants are selected from the group consisting of tris(3,5-di-tert-butyl-4-hydroxybenzyl) isocyanurate, 1,3,5-tris-(3,5-di-tert-butyl-4-hydroxybenzyl)-2,4,6-trimethylbenzene, the calcium salt of the monoethyl ester of 3,5-di-tert-butyl-4-hydroxybenzylphosphonic acid, pentaerythritol tetrakis[3-(3,5-di-tert-butyl-4-hydroxyphenyl) propionate] and octadecyl 3-(3,5-di-tert-butyl-4-hydroxyphenyl) propionate, N,N-di(C.sub.16-C.sub.18alkyl)hydroxylamine, a tris(2,4-di-tert-butylphenyl) phosphite/N,N-di(C.sub.16-C.sub.18alkyl)hydroxylamine combination, di(C.sub.16-C.sub.18)alkyl methyl amine oxide, a tris(2,4-di-tert-butylphenyl) phosphite/di(C.sub.16-C.sub.18)alkyl methyl amine oxide combination, a tris(2,4-di-tert-butylphenyl) phosphite/pentaerythritol tetrakis[3-(3,5-di-tert-butyl-4-hydroxyphenyl) propionate] combination, a tris(2,4-di-tert-butylphenyl) phosphite/octadecyl 3-(3,5-di-tert-butyl-4-hydroxyphenyl) propionate combination, N,N-di(C.sub.16-C.sub.18alkyl)hydroxylamine, a tris(2,4-di-tert-butylphenyl) phosphite/N,N-di(C.sub.16-C.sub.18alkyl)hydroxylamine combination, di(C.sub.16-C.sub.18)alkyl methyl amine oxide, or a tris(2,4-di-tert-butylphenyl) phosphite/di(C.sub.16-C.sub.18)alkyl methyl amine oxide combination.

15. The polyolefin composition of claim 2, wherein the polyolefin substrate has incorporated therein: the one or more ultraviolet light absorbers, in total, from about 0.10 to about 2.5 weight percent, the one or more hindered amine light stabilizers, in total, from about 0.10 to about 1.9 weight percent, the one or more antioxidants, in total, from about 0.05 to about 1.0 weight percent, one or more colorants, in total, from about 0.10 to about 3.0 weight percent, one or more flame retardants, in total, from about 1 to about 70 weight percent, and optionally, one or more antimicrobial compounds, in total, from about 0.001 to about 5.0 weight percent, the weight percents being based on the weight of the polyolefin substrate.

16. The polyolefin composition of claim 1, wherein the polyolefin composition is incorporated into an extruded article selected from the group consisting of house siding, cladding, soffit, and roofing.

17. A polyolefin composition comprising a polyolefin substrate selected from the group consisting of polyethylene, polypropylene, ethylene/propylene copolymer, and a mixture of any two or more thereof, the polyolefin substrate having incorporated therein: a nucleating agent that comprises from about 12 ppm to about 500 ppm by weight based on the weight of the polyolefin substrate; and a filler that comprises from about 15 to about 40 weight percent based on the weight of the polyolefin substrate; wherein: the composition exhibits an impact strength of >35 in-lb measured according to ASTM D4226, and a coefficient of linear thermal expansion of <4.510E-05 in/in/ft measured according to ASTM D696.

18. The polyolefin composition of claim 17, wherein the polyolefin substrate has further incorporated therein one or more additional additives selected from the group consisting of: an ultraviolet light absorber; a hindered amine light stabilizer; an antioxidant; a colorants; a flame retardant; and an antimicrobial compound.

19. The polyolefin composition of claim 17, wherein the nucleating agent comprises sodium benzoate, 2,2-methylene-bis(4,6-di-tert-butylphenyl)phosphate, zinc glycerolate, calcium salt of 1,2-dicarboxylic acid cyclohexane, aromatic trisamide compounds, cis-endo-bicyclo-[2.2.1]-heptane-2,3-dicarboxylic acid disodium salt, aluminum hydroxy-bis[4-(tert-butyl)benzoate] and sorbitols such as 1,3:2,4-bis(3,4-dimethyl-benzylidene)sorbitol 1,3:2,4-bis(4-methylbenzylidene)sorbitol, or 1,3:2,4-bis(3,4-dimethylbenzylidene)sorbitol.

20. The polyolefin composition of claim 17, wherein the one or more fillers comprise natural fibers or an inorganic filler.

21. The polyolefin composition of claim 20, wherein the inorganic filler comprises one or more of calcium carbonate, magnesium hydroxide, talc, wollastonite, or fly ash.

22. The polyolefin composition of claim 17, wherein the nucleating agent comprises an aromatic trisamide compound.

23. The polyolefin composition of claim 17, wherein the polyolefin composition is incorporated into an extruded article selected from the group consisting of house siding, cladding, soffit, and roofing.

24. A polyolefin composition comprising a polyolefin substrate having incorporated therein a nucleating agent, a filler, a hydroxybenzoate ultraviolet light absorber, a high molecular weight hindered amine and a low molecular weight hindered amine, an antioxidant, a colorant, a flame retardant, and an acrylic processing aid.

25. The polyolefin composition of claim 24, wherein the nucleating agent comprises sodium benzoate, 2,2-methylene-bis(4,6-di-tert-butylphenyl)phosphate, zinc glycerolate, calcium salt of 1,2-dicarboxylic acid cyclohexane, aromatic trisamide compounds, cis-endo-bicyclo-[2.2.1]-heptane-2,3-dicarboxylic acid disodium salt, aluminum hydroxy-bis[4-(tert-butyl)benzoate] and sorbitols such as 1,3:2,4-bis-(3,4-dimethyl-benzylidene)sorbitol 1,3:2,4-bis(4-methylbenzylidene)sorbitol or 1,3:2,4-bis(3,4-dimethylbenzylidene)sorbitol.

26. The polyolefin composition of claim 24, wherein the filler comprises natural fibers or an inorganic filler.

27. The polyolefin composition of claim 24, wherein the polyolefin composition is incorporated into an extruded article selected from the group consisting of house siding, cladding, soffit, and roofing.

Description

EXAMPLES

Example 1 Polypropylene Copolymer

[0174] The formulations are dry blended together with polypropylene copolymer and compounded in an extruder to form 2260 mil bars. Weight percent levels of the hindered amines employed are found in the table below. Each formulation further contains 20 weight percent calcium carbonate filler. Each formulation also contains 0.20 weight percent of 5-chloro-2-(3-t-butyl-2-hydroxy-5-methylphenyl)-2H-benzotriazole, 0.40 weight percent of a tris(2,4-di-tert-butylphenyl) phosphite/pentaerythritol tetrakis[3-(3,5-di-tert-butyl-4-hydroxyphenyl) propionate] combination, 1.0 weight percent titanium dioxide and 15 weight percent of the condensate of melamine phosphate and pentaerythritol. All weight percents are based on the weight of polypropylene copolymer.

TABLE-US-00001 Formu- lation (2) (20) BIN1 BIN2 BIN3 TER1 TER2 1 0.4 2 1.0 3 0.4 4 1.0 5 0.4 6 0.4 7 1.0 8 0.4 9 0.4 10 1.0 11 0.4 12 0.4 13 1.0 14 0.4 15 1.0 16 0.4 17 1.0

[0175] The hindered amines are those identified in the detailed description. BIN1 is a binary combination of hindered amines (2) and (36). BIN2 is a binary combination of hindered amines (2) and (45). BIN3 is a binary combination of hindered amines (20) and (45). Formulations 5, 7, 8, 10, 11 and 13 contain 1:1 weight ratios of the binary combinations. Formulation 6 contains 0.3% of hindered amine (2) and 0.1% of hindered amine (36). Formulation 9 contains 0.3% of hindered amine (2) and 0.1% of hindered amine (45). Formulation 12 contains 0.3% of hindered amine (20) and 0.1% hindered amine (45). TER1 is a ternary combination of hindered amines (2), (45) and (14). TER2 is a ternary combination of hindered amines (20), (45) and (14). Formulation 14 contains 0.2% hindered amine (2), 0.14% hindered amine (45) and 0.06% hindered amine (14). Formulation 15 contains 0.5% hindered amine (2), 0.35% hindered amine (45) and 0.15% hindered amine (14). Formulation 16 contains 0.2% hindered amine (20), 0.14% hindered amine (45) and 0.06% hindered amine (14). Formulation 17 contains 0.5% hindered amine (20), 0.35% hindered amine (45) and 0.15% hindered amine (14).

[0176] Formulations 1-17 are repeated, replacing 20% calcium carbonate with 40% calcium carbonate to produce formulations 18-34, respectively. Formulations 1-17 are repeated, replacing 20% calcium carbonate with 20% talc to produce formulations 35-51, respectively. Formulations 1-17 are repeated, replacing 20% calcium carbonate with 40% talc to produce formulations 52-68, respectively. Formulations 1-17 are repeated, replacing 20% calcium carbonate with 20% wollastonite to produce formulations 69-85, respectively. Formulations 1-17 are repeated, replacing 20% calcium carbonate with 40% wollastonite to produce formulations 86-102 respectively. The bars of formulations 1-102 are tested for flame retardancy and color stability after accelerated weathering.

Example 2 High Density Polyethylene

[0177] The formulations are dry blended together with high density polyethylene (HDPE) and compounded in an extruder to form 2260 mil bars. Weight percent levels of the hindered amines employed are in the table below. Each formulation further contains 20 weight percent calcium carbonate filler.

[0178] Each formulation also contains 0.20 weight percent of 5-chloro-2-(3-t-butyl-2-hydroxy-5-methylphenyl)-2H-benzotriazole, 0.40 weight percent of a tris(2,4-di-tert-butylphenyl) phosphite/pentaerythritol tetrakis[3-(3,5-di-tert-butyl-4-hydroxyphenyl) propionate] combination, 1.0 weight percent titanium dioxide and 15 weight percent of the condensate of melamine phosphate and pentaerythritol. All weight percents are based on the weight of polyethylene.

TABLE-US-00002 Formu- lation (2) (36) (45) (20) BIN1 BIN2 BIN4 TER2 TER3 103 0.2 104 0.5 105 0.2 106 0.5 107 0.2 108 0.5 109 0.2 110 0.5 111 0.2 112 0.5 113 0.2 114 0.5 115 0.2 116 0.5 117 0.2 118 0.5 119 0.2 120 0.5

[0179] The hindered amines are those identified in the detailed description. BIN4 is a binary combination of hindered amines (2) and (20). Formulations 111-116 contain 1:1 weight ratios of the binary combinations. Formulation 117 contains 0.1% hindered amine (20), 0.07% hindered amine (45) and 0.03% hindered amine (14). Formulation 118 contains 0.25% hindered amine (20), 0.175% hindered amine (45) and 0.075% hindered amine (14). Formulation 119 contains 0.1% hindered amine (36), 0.07% hindered amine (2) and 0.03% hindered amine (14). Formulation 120 contains 0.25% hindered amine (36), 0.175% hindered amine (2) and 0.075% hindered amine (14). Formulations 103-120 are repeated, replacing 20% calcium carbonate with 40% calcium carbonate to produce formulations 121-138, respectively. Formulations 103-120 are repeated, replacing 20% calcium carbonate with 20% talc to produce formulations 139-156, respectively. Formulations 103-120 are repeated, replacing 20% calcium carbonate with 40% talc to produce formulations 157-174, respectively. Formulations 103-120 are repeated, replacing 20% calcium carbonate with 20% wollastonite to produce formulations 175-192, respectively. Formulations 103-120 are repeated, replacing 20% calcium carbonate with 40% wollastonite to produce formulations 192-210, respectively. The bars of formulations 103-210 are tested for flame retardancy and color stability after accelerated weathering.

Example 3. Polypropylene Copolymer

[0180] Example 1 is repeated, replacing 5-chloro-2-(3-t-butyl-2-hydroxy-5-methylphenyl)-2H-benzotriazole with a UVA selected from 2-(3,5-bis--cumyl-2-hydroxyphenyl)-2H-benzotriazole, 4, 6-diphenyl-2-(4-hexyl oxy-2-hydroxyphenyl)-s-triazine, 4,6-bis-(2,4-dimethylphenyl)-2-(2-hydroxy-4-octyloxyphenyl)-s-triazine, hexadecyl 3,5-di-tert-butyl-4-hydroxybenzoate and 2,4-di-tert-butylphenyl 3,5-di-tert-butyl-4-hydroxybenzoate; replacing the tris(2,4-di-tert-butylphenyl) phosphite/pentaerythritol tetrakis[3-(3,5-di-tert-butyl-4-hydroxyphenyl) propionate] combination with an antioxidant selected from a tris(2,4-di-tert-butylphenyl) phosphite/octadecyl 3-(3,5-di-tert-butyl-4-hydroxyphenyl) propionate combination, N,N-di(C.sub.16-C.sub.18alkyl)hydroxylamine, a tris(2,4-di-tert-butylphenyl) phosphite/N,N-di(C.sub.16-C.sub.18alkyl)hydroxylamine combination, di(C.sub.16-C.sub.18)alkyl methyl amine oxide and a tris(2,4-di-tert-butylphenyl) phosphite/di(C.sub.16-C.sub.18)alkyl methyl amine oxide combination; replacing the calcium carbonate, talc and wallastonite with magnesium hydroxide or fly ash; and replacing the condensate of melamine phosphate and pentaerythritol with a flame retardant selected from melamine polyphosphate, ammonium polyphosphate and a combination of antimony trioxide with decabromodiphenyl ether or tris[3-bromo-2,2-bis(bromomethyl)propyl]phosphate.

Example 4. High Density Polyethylene

[0181] Example 2 is repeated, replacing 5-chloro-2-(3-t-butyl-2-hydroxy-5-methylphenyl)-2H-benzotriazole with a UVA selected from 2-(3,5-bis--cumyl-2-hydroxyphenyl)-2H-benzotriazole, 4,6-diphenyl-2-(4-hexyloxy-2-hydroxyphenyl)-s-triazine, 4,6-bis-(2,4-dimethylphenyl)-2-(2-hydroxy-4-octyloxyphenyl)-s-triazine, hexadecyl 3,5-di-tert-butyl-4-hydroxybenzoate and 2,4-di-tert-butylphenyl 3,5-di-tert-butyl-4-hydroxybenzoate; replacing the tris(2,4-di-tert-butylphenyl) phosphite/pentaerythritol tetrakis[3-(3,5-di-tert-butyl-4-hydroxyphenyl) propionate] combination with an antioxidant selected from a tris(2,4-di-tert-butylphenyl) phosphite/octadecyl 3-(3,5-di-tert-butyl-4-hydroxyphenyl) propionate combination, N,N-di(C.sub.16-C.sub.18alkyl)hydroxylamine, a tris(2,4-di-tert-butylphenyl) phosphite/N,N-di(C.sub.16-C.sub.18alkyl)hydroxylamine combination, di(C.sub.16-C.sub.18)alkyl methyl amine oxide and a tris(2,4-di-tert-butylphenyl) phosphite/di(C.sub.16-C.sub.18)alkyl methyl amine oxide combination; replacing the calcium carbonate, talc and wallastonite with magnesium hydroxide or fly ash; and replacing the condensate of melamine phosphate and pentaerythritol with a flame retardant selected from melamine polyphosphate, ammonium polyphosphate and a combination of antimony trioxide with decabromodiphenyl ether or tris[3-bromo-2,2-bis(bromomethyl)propyl]phosphate.

Example 5. Polypropylene Homopolymer

[0182] Examples 1-4 are repeated replacing the polyolefin with polypropylene homopolymer.

Example 6. High Melt Strength Polypropylene

[0183] ExxonMobil high melt strength polypropylene homopolymer 5341E1 is cryogenically ground to powder form, to which are blended powdered additives, talc inorganic reinforcing filler, calcium carbonate lubricant, powdered colorant and 500 ppm of IRGANOX B-215 as processing and heat stabilizer. Formulations are fed via single gravimetric feeder at 12 pounds/hour feed rate to a COPERION 25 mm corotating twin screw extruder at set temperature 220 C., 150 rpm screw speed. Extruded polymer strands are cooled in a water bath and pelletized to granule form.

[0184] Talc is Specialty Minerals ULTRATALC 609, cColorant is Ocean Blue pigment, IRGANOX B-215 is a 2:1 weight blend of tris(2,4-ditert-butylphenyl)phosphite, and pentaerythritol tetrakis[3-[3,5-di-tert-butyl-4-hydroxyphenyl]propionate]. Formulations prepared are as follows, where the wt % is based on polypropylene: [0185] 1: blank polypropylene [0186] 2: 0.4% HALS (2) [0187] 3: 0.2% HALS (2)/0.2% HALS (36) [0188] 4: 0.3% HALS (2)/0.1% HALS (36) [0189] 5: 0.2% HALS (2)/0.14% HALS (36)/0.06% hexadecyl 3,5-di-tert-butyl-4-hydroxybenzoate [0190] 6: 0.2% HALS (2)/0.2% HALS (45) [0191] 7: 0.3% HALS (2)/0.1% HALS (45) [0192] 8: 0.2% HALS (2)/0.14% HALS (45)/0.06% hexadecyl 3,5-di-tert-butyl-4-hydroxybenzoate [0193] 9: 0.4% HALS (20) [0194] 10: 0.2% HALS (20)/0.2% HALS (45) [0195] 11: 0.2% HALS (14)/0.2% HALS (45) [0196] 12: 0.2% HALS (2)/0.14% HALS (45)/0.06% HALS (14) [0197] 13: 0.2% HALS (2)/0.14% HALS (45)/0.06 hexadecyl 3,5-di-tert-butyl-4-hydroxybenzoate [0198] 14: 0.2% HALS (2)/0.14% HALS (45)/0.06% HALS (14)/0.04% 5-chloro-2-(3-t-butyl-2-hydroxy-5-methylphenyl)-2H-benzotriazole [0199] 15: 0.2% HALS (2)/0.14% HALS (45)/0.06% hexadecyl 3,5-di-tert-butyl-4-hydroxybenzoate/0.04% 5-chloro-2-(3-t-butyl-2-hydroxy-5-methylphenyl)-2H-benzotriazole [0200] 16: 0.14% HALS (45)/0.06% HALS (14)/0.2% HALS (20) [0201] 17: 0.14% HALS (45)/0.06% hexadecyl 3,5-di-tert-butyl-4-hydroxybenzoate/0.2% HALS (20)

[0202] Formulations are injection molded to 60 mil thick plaques, 1.75 in.2.5 in., using BOY 50 injection molding machine with setpoint temperature 450 F., mold temperature 65 F. Three replicate plaques of each formulation are then mounted on frames and subjected to accelerated light aging/weathering using an Atlas Ci65A xenon Weather-O-Meter (WOM), per ASTM G155 cycle 1 (irradiance 0.35 W/m.sup.2, black panel temperature 63 C., cycles 102 minutes light and 18 minutes light with water spray, with inner & outer light filters borosilicate.)

[0203] Results for the average readings after 1912 hours of weathering are presented in the following table:

TABLE-US-00003 Formulation E Initial 60 gloss 60 gloss 60 gloss 1 22.6 50.7 2.5 48.2 2 0.7 50.0 29.8 20.3 3 0.7 54.9 32.8 22.0 4 0.8 56.6 33.7 22.9 5 0.9 57.3 47.5 9.7 6 0.6 56.2 34.3 21.9 7 0.8 56.9 33.6 23.3 8 1.0 56.9 46.9 10.0 9 8.9 60.2 5.0 55.2 10 0.8 58.6 36.7 21.9 11 0.9 44.7 32.3 12.4 12 0.8 49.7 34.5 15.2 13 1.0 50.9 45.0 6.0 14 0.9 50.1 36.9 13.2 15 1.0 50.9 44.3 6.6 16 0.9 50.9 36.5 14.4 17 1.0 51.3 44.3 7.0

[0204] Formulations 5, 8, and 11-17 show excellent results.

Example 7. Polypropylene Copolymer

[0205] The substrate is polypropylene impact copolymer PROFAX SG702 in pellet form. The filler is Heritage Plastics HT6P commercial masterbatch (60% talc in polypropylene copolymer). Filler is let down to 20% in all formulations.

[0206] Procedure: [0207] 1. Bag Mixing 1 kg [0208] 2. Compounding @ 200 C. [0209] 3. Injection Molding @ 220 C. (plaque thickness 60 mil for Weather-o-Meter exposures) [0210] 4. Periodic reading of color and gloss [0211] 5. Microscopy for microcracking and exudation [0212] 6. Regular spray weathering with intervals at 0, 500, 1000, 2000, 3000, 4000 hrs, etc.

[0213] The following formulations are prepared. Additives are present at 0.75 weight percent based on polypropylene. Multi-coponent additive mixtures contain individual additives in equal weight percent. [0214] 1: hexadecyl 3,5-di-tert-butyl-4-hydroxybenzoate [0215] 2: 2,4-di-t-butyl phenyl 3,5-di-t-butyl-4-hydroxybenzoate [0216] 3: HALS (2) [0217] 4: HALS (2)/hexadecyl 3,5-di-tert-butyl-4-hydroxybenzoate [0218] 5: HALS (14) [0219] 6: HALS (14)/hexadecyl 3,5-di-tert-butyl-4-hydroxybenzoate [0220] 7: HALS (36) [0221] 8: HALS (36)/hexadecyl 3,5-di-tert-butyl-4-hydroxybenzoate [0222] 9: HALS (2)/HALS (14)/HALS (45) [0223] 10: HALS (2)/HALS (14)/HALS (45)/hexadecyl 3,5-di-tert-butyl-4-hydroxybenzoate [0224] 11: HALS (2)/HALS (14)/HALS (45)/2,4-di-t-butyl phenyl 3,5-di-t-butyl-4-hydroxybenzoate [0225] 12: HALS (20)/hexadecyl 3,5-di-tert-butyl-4-hydroxybenzoate/HALS (39)/4,6-bis-(2,4-dimethylphenyl)-2-(2-hydroxy-4-octyloxyphenyl)-s-triazine (0.41 weight percent total)

[0226] The results of E color change after accelerated weathering at 1500 hours and 4000 hours are below:

TABLE-US-00004 Formulation 1500 hours 4000 hours 1 18.2 2 16.5 3 3.8 3.7 4 4.0 3.5 5 6.8 6.7 6 5.3 4.9 7 3.3 3.7 8 3.5 2.9 9 3.0 2.9 10 3.5 2.9 11 2.1 2.0 12 3.8 3.5

[0227] Excellent results are achieved with formulations containing HALS and a benzoate UV absorber.

[0228] The following additional formulations are employed for gloss retention studies: [0229] 1a: 0.15% hexadecyl 3,5-di-tert-butyl-4-hydroxybenzoate [0230] 2a: 0.15% 2,4-di-t-butyl phenyl 3,5-di-t-butyl-4-hydroxybenzoate [0231] 13a: 0.15% HALS (2)/HALS (14)/HALS (45) [0232] 14a: 0.15% HALS (2)/HALS (14)/HALS (45)/hexadecyl 3,5-di-tert-butyl-4-hydroxybenzoate [0233] 15a: 0.15% HALS (2)/HALS (14)/HALS (45)/2,4-di-t-butyl phenyl 3,5-di-t-butyl-4-hydroxybenzoate

[0234] Percent 60 gloss retention at various time intervals are found below:

TABLE-US-00005 1000 1500 2000 3000 4000 Formulation hours hours hours hours hours 1a 25% 13% 1 29% 15% 2a 29% 14% 2 38% 14% 13a 86% 82% 52% 13% 8% 13 88% 78% 64% 43% 26% 14a 89% 89% 88% 36% 11% 15a 87% 87% 79% 20% 10% 15 85% 84% 83% 81% 74%

[0235] Combinations of hindered amine stabilizers and benzoate UV absorbers provide outstanding gloss retention upon accelerated weathering.

Example 8. Flame Retardancy of Polypropylene Homopolymer

[0236] ExxonMobil high melt strength polypropylene homopolymer 5341E1 is dry blended with the listed additives, 0.5% zinc stearate, and 0.1% IRGANOX B-225 thermal stabilizer. Formulations are extrusion compounded on 25 mm twin screw extruder at 195-205 C. set temperatures run at 200 rpm and 20 kg/hr feed rate. Compounded formulations are injection molded into UL-94 vertical burn test specimens 0.1255.00.5 inches dimensions. IRGANOX B-225 is a 1:1 weight blend of tris(2,4-ditert-butylphenyl)phosphite and pentaerythritol tetrakis[3-[3,5-di-tert-butyl-4-hydroxyphenyl]propionate]. The following formulations are prepared. Additives are weight percent based on polypropylene. [0237] 1: controlno flame retardant [0238] 2: 6% AFLAMMIT PCO 960/0.6% HALS (34) [0239] 3: 8% AFLAMMIT PCO 960/0.8% HALS (34) [0240] 4: 6% AFLAMMIT PCO 960/0.6% HALS (47) [0241] 5: 8% AFLAMMIT PCO 960/0.8% HALS (47)

[0242] AFLAMMIT PCO 960 is a proprietary organic phosphorus flame retardant containing 24% phosphorus, available from Thor.

[0243] Combinations of hindered amine stabilizers and benzoate UV absorbers provide outstanding gloss retention upon accelerated weathering.

[0244] Ratings according to the UL-94 V test are as compiled in the following table. UL-94 Test for Flammability of Plastic Materials for Parts in Devices and Appliances, 5th Edition, Oct. 29, 1996.

TABLE-US-00006 Rating Afterflame time Burning drips Burn to Clamp V-0 <10 s no no V-1 <30 s no no V-2 <30 s yes no Fail <30 s yes Fail >30 s no

[0245] Results are below:

TABLE-US-00007 Formulation UL-94 rating 1 no rating 2 V-2 3 V-2 4 V-0 5 V-0

Example 9. Melt Strength Improvement of Polypropylene

[0246] Suitable melt strength is an important property in extruded polymer profile articles. High melt strength is desired to avoid sagging or drooling of polymer film, sheet or profile shaped articles upon the polymer melt exiting the extruder die and during take-up operation in downstream equipment. It has surprisingly been found that improvements in melt strength can be imparted to commercially available high melt strength polypropylenes used as profile extrusion applications via polymer blending in the melt with certain random or block polymers. In particular polyolefin copolymers known as Olefinic Block Copolymers (OBC) such as INFUSE from Dow and VISTAMAXX from ExxonMobil have been found to improve melt strength properties in polypropylene and blends of polypropylene and polyethylene as shown below. A valuable property is melt strength for extruded profile articles. It is shown in the table that while HDPE alone and OBC alone have poor melt strength, certain binary and ternary combinations with a polypropylene, in this case a high melt strength (HMS) polypropylene, exhibit higher melt strength and elongation stress at break, over the HMS PP alone.

[0247] Polypropylene (PP) is ExxonMobil high melt strength polypropylene homopolymer 5341E1. Polyethylene is ALATHON L 5332CP, HDPE from LyondellBasell. Olefinic block copolymers (OBC) are INFUSE 9010 or INFUSE 9100 from Dow or VISTAMAXX 6102 or VISTAMAXX 3020FL from ExxonMobil. PARALOID K 125 is an all acrylic processing aid for vinyl from Dow, Mw 4.0 to 5.0 million, Tg 106 C.

[0248] The following formulations are tested. Percents are by weight. [0249] 1: PP [0250] 2: HDPE [0251] 3: INFUSE 9010 [0252] 4: 90% PP/10% INFUSE 9010 [0253] 5: 90% HDPE/10% INFUSE 9010 [0254] 6: 70% PP/30% HDPE [0255] 7: 63% PP/32% HDPE/5% INFUSE 9010 [0256] 8: 63% PP/27% HDPE/10% INFUSE 9010 [0257] 9: PP [0258] 10: 95% PP/5% INFUSE 9100 [0259] 11: 90% PP/10% INFUSE 9100 [0260] 12: 95% PP/5% VISTAMAXX 6102 [0261] 13: 90% PP/10% VISTAMAXX 6102 [0262] 14: 95% PP/5% VISTAMAXX 3020FL [0263] 15: 90% PP/10% VISTAMAXX 3020FL [0264] 16: PP [0265] 17: 99% PP/1% PARALOID K 125 [0266] 18: 97% PP/3% PARALOID K 125 [0267] 19: 95% PP/5% PARALOID K 125

[0268] Results for formulations 1-8 are below. V.sub.b is speed at break (mm/sec). F is force at break in cN (melt strength). Draw ratio is draw ratio at breakratio of initial speed to speed at break, higher is desired. Elongation stress is elongation stress at break in MPamore extensibility of the polymer melt, higher is desired.

TABLE-US-00008 Formulation V.sub.b F draw ratio elongation stress 1 471.6 22.4 21.0 1.19 2 294.7 15.6 12.0 0.52 3 339.8 9.4 10.9 0.36 4 525.5 25.4 20.8 1.54 5 280.6 14.4 11.3 0.46 6 402.0 24.0 17.8 1.09 7 458.8 24.0 20.9 1.26 8 500.7 25.9 21.3 1.47

[0269] Results for formulations 9-15 are below.

TABLE-US-00009 Formulation V.sub.b F draw ratio elongation stress 9 344.6 17.6 12.8 0.69 10 427.3 23.7 16.6 1.15 11 390.4 21.2 16.4 0.95 12 408.3 20.1 15.0 0.95 13 460.7 19.5 18.6 1.06 14 382.0 16.4 13.6 0.73 15 496.5 22.2 18.5 1.26

[0270] Results for formulations 16-19 are below.

TABLE-US-00010 Formulation V.sub.b F draw ratio elongation stress 16 374.1 18.8 14.5 0.877 17 377.6 16.1 13.7 0.704 18 464.8 21.7 18.4 1.185 19 454.1 21.4 16.9 1.109