HIFLEX TPO Resins Technical Paper

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Hiflex TPO Resins A new family of thermoplastic resins produced with the unique Catalloy process technology

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Section II: About Catalloy TPO Resins

Catalloy Process Technology Catalloy TPO Resins Market Segments & Applications

New Hiflex TPO Resin Technical Information Hiflex TPO Resins Hiflex TPO Resins used in PP Compounds

Section III: Hiflex – new grade

Content

Product Selection Guide

Test Methodology Section IV: References

About LyondellBasell Section I

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Section I: About LyondellBasell

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LyondellBasell At A Glance

• One of the largest plastics, chemical and refining companies

• Annual revenues of $45 billion (2014)

• 13,100 employees worldwide

• Proven proprietary Catalloy process technology, which was introduced 25 years ago.

• The Catalloy process technology produces many Thermoplastic Polyolefins (TPO) still considered benchmarks in popular applications

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Vertically Integrated Portfolio Structure

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Aromatics Fuels

Crude Natural Gas

Refining

Technology Technology

Capturing value along the chain

Natural Gas

Liquids (NGLs)

Styrene Ethylene Oxide Acetyls Polybutene-1 Oxy Fuels

Polypropylene Compounding

Glycols

Glycol Ethers

Butanediol

Glycols

Glycol Ethers

Naphtha

Olefins Crackers Olefins

Polyethylene Polypropylene

Thermoplastic

Polyolefins

Propylene Oxide

• LyondellBasell’s proprietary Catalloy technology combines the advantages of polyolefins with those of elastomers, producing unique and cost-effective materials with a wide range of highly balanced and tailor-made properties.

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Global Presence • LyondellBasell manufactures products at 55 sites in 18 countries.

• With four manufacturing sites in Europe and North America, Catalloy sales and support teams have a global reach to serve customers worldwide.

• Catalloy process resins are sold as easy-to-store and flowable pellets, shipped globally in bulk containers and stored in silos, or in 25 kg bags.

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North America

USA Illinois Iowa Louisiana Michigan New Jersey Ohio Tennessee Texas

Houston Bayport

Mexico

South America

Argentina Brazil

Europe

France Germany Italy Netherlands

Rotterdam Poland Spain United Kingdom

London Asia-Pacific

Australia China

Hong Kong Japan S.Korea Malaysia Thailand Middle East

Saudi Arabia

Administrative Offices/Headquarters Manufacturing Technology Centers Joint Ventures Catalloy Plants

Owned and operated by LyondellBasell subsidiaries and/or joint ventures.

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Section II: About Catalloy TPO Resins

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Thermoplastic Polyolefins (TPO) Resins From The Catalloy Process

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• Catalloy technology is a multi-stage gas phase polymerization process, not just a resin or a product name.

• It produces an innovative family of TPO resins, which are used by our customers as base materials, raw materials in compounds or as polymer modifiers.

• It meets specific customer requirements and can deliver additional value in use through: cost performance, differentiation and property modification.

Note 1: Schematic overview of the unique Catalloy process technology. Independent fluidized bed reactors with multi monomer capability exploiting spherical Ziegler-Natta high mileage catalyst with controlled porosity.

Note 2: The Catalloy process gives the ability to control the rubber composition allowing us to tailor the property¹ envelope of each specific Catalloy grade. ¹Strength, transparency, softness, stiffness, gloss, impact and shrinkage.

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Catalloy TPO Resins: Unique Structures

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• Catalloy TPO resins are not conventional TPOs or mechanical blends.

• These product families are alloys of rubber and polypropylene produced simultaneously in the polymerization reactors, offering much better dispersion of the rubber in the material versus a mechanical blend (compound product) (See Image 1).

• As opposed to elastomers or plastomers, the Catalloy TPO resins do not necessarily require additional off-line blending with polypropylene, thus minimizing complexity

• The good dispersion of rubber in the material has a direct effect on the processing consistency and end-use properties

Image 1

Note 1: Transmission Electron micrographs (TEM) of Hifax CA 10A and a mechanically compounded grade. The uniform dispersion of the amorphous rubber phase (dark areas) in the Hifax material, which yields more consistent processing and end-use properties.

Note 2: TEM (transmission electron microscopy) – 3700X

Ethylene Propylene Rubber Blend Catalloy TPO Resin

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Catalloy TPO Resins: Unique Structures

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• Catalloy TPO resins offer a unique set of properties in one product and can replace other types of polymers (see image 2).

• Catalloy TPO resins can be utilized in all major conversion processes, such as injection and blow molding, sheet extrusion, thermoforming, extrusion coating and film applications.

• Catalloy TPO resins are also used in compounding due to very low modulus and good compatibility with other polymers. Whether a rigid compound, soft compound or a masterbatch, Catalloy grades offer a cost efficient solution as building blocks.

• This enables customers to meet challenging requirements on performance, cost, recyclability and process-ability.

Catalloy

Image 2

Note: Catalloy versus other polymers comparing three key properties: high temperature resistance, flexibility and thermoplastic properties.

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Catalloy TPO Resins: Key Properties Catalloy TPO resins enable the control of key properties such as:

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• Low Density • Stiffness and Impact Balance • Thermal Resistance • Flexibility & Softness • Low-Temperature Impact • Durability / Weather-ability

• Optical Properties • Dimensional Stability • Tear and Puncture Resistance • Compatibility with Polyolefins • Easy Processing • Recyclable

Softell, Hifax, Adflex, Hiflex Moplen Adstif

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Catalloy Product Families: Hifax, Adflex, Softell And Hiflex

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Automotive Building, Construction and Infrastructure Electrical Appliances

Consumer Goods Packaging Textile and Carpets

Catalloy: Utilized In A Wide Range Of Market Segments

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Catalloy Offering Functionality And Long-lasting Performance In Single-ply Roofing

Wire & Cable

Flexible Pipes and Hoses

Applications At A Glance: Building & Construction

LyondellBasell’s thermoplastic polyolefins (TPO) have been specified bycustomers for waterproofing membranes for more than 20 years; including Wembley Stadium in London, Tempodrome in Berlin, Malpensa 2000 Airport in Italy, Sha Tin Race Course in Hong Kong, Seibu Stadium in Japan and Spencer Theatre in US. Catalloy TPO Resins replacing alternative roofing materials, such as PVC, EPDM and Bitumen-membranes. It reduce environmental impact. Catalloy Resins do not contain plasticizers, chlorine or heavy metals. It is suitable for “Green roofs” reducing summer temperatures in city areas. Also suitable for “White roofs” reducing temperatures in buildings. Membranes produced using Catalloy TPO are well proven waterproofing systems that allow excellent long term performance. Catalloy is specified by some major brand names.

“Durability: more than 20 years of proven performance”

• Aesthetics

– Anti-Tiger stripes

– Low Gloss

– High Clarity

• Impact/Stiffness Balance

• Room & Cold Temperature Impact

• Soft touch

• Low shrinkage

• Thermal Resistance

• Durability

• High Softness

• Flexibility

• Good Chemical resistance

• Weight reduction

• High dimensional stability

• High Filler loading absorption

• Recyclability

Accelerated weathering tests

Roofing Membranes

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Hifax and Adflex resins enhance the performance of rigid and flexible packaging Higher performance can be achieved by utilizing Hifax and Adflex resins alone or in blends with other polyolefins. Modification with Catalloy TPO resins in extrusion blow molding and injection molding can enhance the cold-temperature impact performance of transparent applications while retaining clarity. Hifax and Adflex resins can offer attractive haptic properties and a soft touch surface with controllable gloss. Hiflex and Adflex grades can also be used in the manufacture of injection molded containers, crates and bins to improve the impact resistance. They also can offer low warpage, dimensional stability, flexibility and a tight fit when used in these applications.

Impact Modification with Catalloy Process Resins in Rigid Packaging

Applications At A Glance: Packaging

Flexible Packaging

Rigid Packaging

“Room and Cold Temperature Impact”

Izod Impact Strength • Aesthetics


– Low Gloss

– High Clarity



• Soft touch

• Low shrinkage


• Durability

• High Softness

• Flexibility





• Recyclability

Industrial Packaging

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Compounds based on Hifax TPO Resins are used in various Interior and Exterior Applications

Exterior

Under-the-Hood

Applications At A Glance: Automotive (I)

Interior

Controllable gloss, good aesthetics, grain retention, ductile behavior in impact tests and low CLTE are typical requirements for components found on the interior compartment. The high softness and the excellent behavior at both high and low temperatures, combined with haptic (low gloss, soft touch) make the Catalloy TPO resin the product of choice for the development of compounds dedicated to automotive interior parts like consoles, pillar trims, interior flooring, soft grip knobs and skins for dashboard and door panels. Due to their specially designed compositions, Hifax, Adflex and Softell resins are well know in the industry for their excellent impact resistance at room temperature and low temperature resistance, flow mark free (anti-tiger striping) surface and low shrinkage in applications such as bumpers, side cladding and front grills.

“Flow Marks - Asynchronous “Tiger Stripes”

Note: PP/Elastomer/Talc

compound including HX X 1956A

Note: PP/Elastomer/Talc

compound without HX X 1956A

• Aesthetics


– Low Gloss

– High Clarity



• Soft touch

• Low shrinkage


• Durability

• High Softness

• Flexibility





• Recyclability

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Softell TPO Resins replacing engineering plastics for use in demanding customer applications

Applications At A Glance: Automotive (II)

Interior

Softell TPO resins are LyondellBasell's advanced polyolefins which offer an outstanding combination of performance and processing characteristics and are designed for use in demanding technical applications such as automotive interior parts. Due to the outstanding properties of Softell TPO resins, manufacturers are able to produce interior parts with exceptional haptic qualities without the additional need for painting, giving a pleasing aesthetic look to automotive interiors. PP compounds based on Softell TPO resins containing glass fibres offer a unique low gloss surface finish without the need for additional decoration, further enhancing the qualities of the components. The Softell product family combines exceptional performance with the easy processing characteristics of polyolefins. Due to an outstanding property profile, the Softell grades enable the production of finished parts with high-quality surface aesthetics and excellent properties using only one injection molding step.

“Softell CA7413A provides excellent haptic properties such as low gloss and soft touch”

• Aesthetics


– Low Gloss

– High Clarity



• Soft touch

• Low shrinkage


• Durability

• High Softness

• Flexibility





• Recyclability

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Section III: New Grade – Hiflex TPO Resins

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Hiflex TPO Resins- An Innovative Structure

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• LyondellBasell launches Hiflex TPO resins, an innovative family of products developed with the unique Catalloy process technology.

• Due to the flexibility of the Catalloy process a new ‘phase-inverted’ structure - in which the elastomer acts as the matrix and the PP as the modifier - has been developed (See Image 1).

• Hiflex TPO resins combine the uniqueness of LyondellBasell’s existing Hifax and Adflex TPO resins offering easy processing, recyclability, flexibility, weather-ability, weight reduction, high thermal resistance and low gloss, but on top of that an improved impact, stiffness and shrinkage performance balance when used in a compound (See Image 2).

• Hiflex TPO resins offer replacement for highly priced flexible polymers, engineering resins or metallocene based polyolefin elastomers (e.g. C2C4 or C2C8)

Conventional Hifax TPO New Hiflex TPO

Note 1: TEM (transmission electron microscopy) – 3700X.

Note 2: Dark areas represent rubber, while white are crystalline parts.

Note: Comparative performance matrix of Hiflex vs. Hifax Benchmark vs. Polyolefin Elastomers (C2C8 – metallocene catalyst) on neat resin and standard PP Compound (15% talc filled).

Image 1

Image 2

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Hiflex - As Building Block In Your Compounds

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• This new family of resins can be used directly in your process or as building block in your compounds for a wide variety of applications.

• The Hiflex resins together with our in-depth knowledge of TPO compound requirements, enables LyondellBasell to offer a range of solutions based on desired compounding and processing characteristics as well as finished part performance and appearance.

• Learn more about how Hiflex TPO resins can improve your product and process:

1. Neat Resin Comparison: Tests are comparing Hiflex against Hifax and C2C8 benchmark

2. PP Compound Comparison: Tests are based on comparing PP compounds (Filled and Unfilled) replacing C2C8 elastomer with Hiflex TPO Resins 1:1 and 1:2 (Filled) / 1:1.4 (Unfilled)

Note: Neat Resin Basic Data - Injection molded bars (according ISO standard)

Technical Data Hiflex CA7600A

Hiflex TPO Resins in a PP Compound

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Hiflex - Neat Resin Comparison

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Flowability Storage Modulus Glass Transition Temperature (Tg)

Catalloy TPO resins in general [e.g. Hiflex and Hifax] are sold as free flowing pellets. Hiflex keeps this advantage of free flowing pellets even at high temperature (60 C). The advantage of free flowing pellets improves ease and efficiency of handling and processing as well as simplifies logistics with possibility of silo storage.

Hiflex TPO resins provide a significant advantage in thermal resistance compared to conventional C2C8 elastomers. Above data shows the superior thermal stability of the Hiflex TPO resins compare to C2C8 elastomers; C2C8 elastomers soften significantly at +/-40ᵒC, while the unique structure of the Hiflex TPO resins allow an exceptional resistance even above 100 C.

Hiflex TPO resins show a significant lower Tg value – leading to excellent impact behavior at very low temperatures - in comparison with conventional C2C8 elastomer.

Handling / Storage Thermal Properties (DMTA)

Note: C2C8 polyolefin elastomer benchmark based on metallocene catalyst

Plu

gged

Plu

gged

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Hiflex - Neat Resin Comparison

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Cross-Linking Fluidity after high filler loading

Peroxide/Co-agent cross-linking approach on Hiflex TPO resins is a method to improve its elastic response (see data table). Despite fact that cross-linking performance of a Catalloy TPO resin cannot be compared with C2-elastomers, it shows however the advantage of Hiflex being able to remain a thermoplastic material after crosslinking, while the C2-elastomer structure change to a thermoset. Therefore, Hiflex TPO resins give the opportunity of easy re-processing after cross-linking.

Chemical Reactivity Filler Loading Capability

Hiflex can be used in high filled applications. The filler loading evaluation shows the capability of the Hiflex neat resin to incorporate similar amount of filler as C2C8 elastomers and more filler than Hifax. The processability is improved when compared to Hifax.

Note: Data (before and after XL) refer to compression molded plaques

Source: Data generated with laboratory scale equipment

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Hiflex – Filled and Unfilled PP Compounds

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MFR Spiral¹

Using Hiflex TPO resins as modifier in unfilled and filled compounds will lead to improved processing behavior. In filled compounds based on 20% Hiflex TPO resins, an MFR of more than 17 can be achieved.

The spiral flow test confirms the excellent process-ability of Hiflex TPO resins even at high modification level (see test method description).

Processing

¹Method of evaluating the mold flow of a resin to injection in which the melt is injected into a spiral runner of constant trapezoidal cross section with numbered and subdivided marked along the runner. The mold is filled from a gate at the center. The maximum flow length at constant P and T is recorded.

Vicat Softening Point

At similar modification level the compound based on Hiflex presents a superior thermal resistance compared to compounds based on C2C8 elastomers.

Thermal Properties

²Unfilled Compounds contain LyondellBasell’s new low emission, high flow homo polymer (Moplen HP500W); Catalloy or C2C8 Modifier and Black Pigmented Masterbatch.

³Filled Compounds contain Moplen PP; Catalloy or C2C8 Modifier and 15% Talc.

UN

FILL

ED²

FILL

ED³

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Hiflex – Filled and Unfilled PP Compounds

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Aesthetics

A significant reduction of gloss in both unfilled and filled compounds is observed when modified with Hiflex TPO resins.

Scratch Resistance Impact / Stiffness Balance

The balance of Impact/Stiffness properties is improved when using the Hiflex TPO resins (especially compare to any of the existing Hifax TPO benchmark resins).

Mechanical Properties

Whether it is filled or unfilled compound at similar or higher Hiflex TPO resin content, scratch resistance is better in all cases. Property is measured at 10N and 15N.

Specular Gloss

UN

FILL

ED

FILL

ED

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Hiflex – Great Impact, Stiffness and Shrinkage Balance

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Hiflex in a PP Compound offers¹:

• Similar to lower

shrinkage vs. C2C8 elastomers

• Improved impact performance vs. Hifax benchmark

• Similar stiffness compare to C2C8 elastomers

• Better flowability and processability

• Better aesthetics • Competitive costs

¹Based on a 12% talc filled compound, including impact masterbatch and mid flow standard heco

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Hiflex – Great Impact, Stiffness and Shrinkage Balance

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Impact, Stiffness and Shrinkage Comparison

Impact @ -30ᵒC Impact @ -20ᵒC

Note: Based on a 12% talc filled compound, including impact masterbatch and mid flow standard heco

*Bubble size corresponds to average shrinkage. *Bubble size corresponds to average shrinkage.

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Section IV: References

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Test Method Reference • MFR: ISO 1133 • Flexural Modulus: ISO 178 • Tensile Properties: ISO 527-1,-2 • Charpy impact: ISO 179-1 • Heat Distortion Temperature: ISO 75-2 • Vicat: ISO 306/A50 • Gloss : ISO 67530 • Shore Hardness: ISO 868 • Scratch resistance: GME 60280 • Tg (DMTA): Internal Method 3°C/min, 1 Hz • Storage Modulus (DMTA): Internal Method, 3°C/min, 1Hz • Compression set: ISO 815-1-2

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Contacts Contact our team in case of further questions: Samuel Martinez Marketing Manager PP/Catalloy [email protected] Office: +31 (0)10 275 4295 Mobile: +31 (0)653 718062 Vincent Baudier Application Development Engineer Catalloy [email protected] Office: +32 10 81 42 15 Mobile: +32 476 98 26 96 Gisella Biondini Application Development Engineer Catalloy [email protected] Office: +39 0532 46 7917 Mobile: +39 348 91 50 710

You can find out more about us by visiting our website at: www.lyb.com

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Disclaimer and Trademarks Before using a product sold by a company of the LyondellBasell family of companies, users should make their own independent determination that the product is suitable for the intended use and can be used safely and legally. SELLER MAKES NO WARRANTY; EXPRESS OR IMPLIED (INCLUDING ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE OR ANY WARRANTY) OTHER THAN AS SEPARATELY AGREED TO BY THE PARTIES IN A CONTRACT. LyondellBasell prohibits or restricts the use of its products in certain applications. For further information on restrictions or prohibitions of use, please contact a LyondellBasell representative. Users should review the applicable Safety Data Sheet before handling the product. Catalloy, Spherizone, Softell, Hifax, Adflex, Moplen, Adstif and Hiflex are trademarks owned or used by the LyondellBasell family of companies. Softell, Hifax and Moplen are registered in the U.S. Patent and Trademark Office. Any technical advice, assistance, recommendations, testing or reports provided by the LyondellBasell (“LYB”) family of companies to you for any reason, including, but not limited to (i) the selection, processing or use of a LYB product, (ii) the storing, handling or usage of a LYB product, or (iii) the modification of a LYB product in an end-use application, or (iv) assistance about technical feasibility of applications, or (v) assistance about design and simulation methods or procedures (collectively, “Technical Assistance”) is given and accepted at your sole risk and without any warranty whatsoever. LyondellBasell will have no liability or responsibility for the use of, results obtained from, or any other aspects of the Technical Assistance, including, but not limited to, the preparation and delivery hereof. You are encouraged to verify independently any such Technical Assistance

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HIFLEX TPO Resins Technical Paper