Initially developed to overcome the limited low-temperature impact resistance of polypropylene (PP) and allow its application in subzero temperatures, the PP/elastomer blends became a very important and industrially relevant material class. Within the last 40 years, a whole range of PP impact copolymers from multireactor processes have been developed that are capable of covering wide application areas. This review summarizes their developmental history and presents options for the in-reactor design of these polymers and their modification by compounding with elastomers and fillers or reinforcements after the polymerization. An overview of the application range is also presented together with a glimpse into the future of this material class.

Heterophasic copolymers comprised of polypropylene (PP) matrix and ethylene-propylene copolymer (EPC) dispersed phase were investigated with respect to the dispersed phase composition, i.e., ethylene/propylene ratio. The rheological properties, morphology, as well as thermal and mechanical relaxation behavior were studied to describe the structure evolution and phase interactions between the components of the PP copolymers. Decrease of the ethylene content of the EPC leads to a higher matrix-dispersed phase compatibility, as evaluated by the shift of the glass transition temperatures of EPC and PP towards each other. At ethylene content of EPC of 17 wt %, the glass transition temperatures of the both phases merged into a joint relaxation. The effect of the EPC composition on the internal structure of the dispersed domains and on the morphology development of the heterophasic copolymers was demonstrated. Decreasing ethylene content was found to induce a refinement of the dispersed phase with several orders of magnitude down to 0.18 m for propylene-rich EPC. Optical microscopy observations showed that the dispersed propylene-rich phase is preferably rejected at the interlamellar regions of the spherulites and/or at the interspherulitic regions, while the ethylene-rich domains are engulfed within the PP spherulites. Both of these processes impose an additional energetic barrier and influence the spherulite growth rate of the heterophasic materials.

PP was modified with elastomer and wood to prepare materials with large stiffness and impact resistance. Three wood fibers with different particle characteristics were used, and elastomer as well as wood content changed in a wide range. and to increase the plastic deformation of the matrix polymer.

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The optical properties of polypropylene (PP) were modified by nine different sorbitol type clarifiers available commercially or synthesized in the study. The solubility of the clarifiers in PP was estimated by thermodynamic model calculations. The results showed that the solubility of these additives in PP is small, a few 1000 ppm at most. Solubility is determined by the chemical structure of the sorbitol, and the heat of fusion of the latter changes solubility by at least one order of magnitude. Solubility can be estimated reasonably by the Flory-Huggins lattice theory. The morphology of most sorbitols transforms at a temperature much below their melting point upon heating. This transformation, which is accompanied by crystal perfection, seems to influence melting and solubility. A fibrillar structure forms upon the cooling of molten sorbitols, but the diameter of the fibrils is much larger than those forming in the polymer melt. The nucleating effect of the clarifier depends on solubility, but also on processing conditions. Nucleus density is related to the amount of dissolved clarifier. A close correlation was found between the Flory-Huggins interaction parameter of sorbitols and the smallest achievable haze, which can be explained by the effect of solubility and nucleus density.