Hiflex TPO Resins

A new family of thermoplastic resins

produced with the unique Catalloy
process technology

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Content
Section I

About LyondellBasell

Section II:

Catalloy Process Technology

About Catalloy

Catalloy TPO Resins

TPO Resins

Market Segments & Applications

Section III:
Hiflex new grade

New Hiflex TPO Resin

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

Section IV:

Product Selection Guide

References

Test Methodology

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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

LyondellBasells 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.

Natural Gas

Crude

Natural Gas

Refining

Liquids (NGLs)
Naphtha

Polyethylene

Polypropylene

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Thermoplastic
Polyolefins

Propylene
Oxide

Glycols
Glycol Ethers
Butanediol

Acetyls

Ethylene
Oxide

Glycols
Glycol Ethers

Styrene

Technology

Polypropylene
Compounding

Polybutene-1

Olefins

Capturing value along the chain

Oxy Fuels

Olefins
Crackers

Aromatics

Technology

Fuels

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.
North America

Europe

USA
Illinois
Iowa
Louisiana
Michigan
New Jersey
Ohio
Tennessee
Texas
Houston
Bayport
Mexico

France
Germany
Italy
Netherlands
Rotterdam
Poland
Spain
United Kingdom
London
Asia-Pacific
Australia
China
Hong Kong
Japan
S.Korea
Malaysia
Thailand

South America
Argentina
Brazil

Middle East
Administrative Offices/Headquarters

Manufacturing

Technology Centers

Joint Ventures

Catalloy Plants

Saudi Arabia

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
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,

It meets specific customer requirements and can

deliver additional value in use through: cost
performance, differentiation and property
modification.

which are used by our customers as base

materials, raw materials in compounds or as
polymer modifiers.

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 property envelope of each specific Catalloy
grade.
Strength, transparency, softness, stiffness, gloss, impact
and shrinkage.

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Catalloy TPO Resins: Unique Structures

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

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Image 1
Ethylene Propylene Rubber Blend

Catalloy TPO Resin

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

Catalloy TPO Resins: Unique Structures

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.
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Image 2

Catalloy

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:

Low Density
Stiffness and Impact Balance
Thermal Resistance
Flexibility & Softness
Low-Temperature Impact

Durability / Weather-ability

Softell, Hifax, Adflex, Hiflex

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

Recyclable

Moplen

Adstif

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Catalloy Product Families: Hifax, Adflex, Softell And Hiflex

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Catalloy: Utilized In A Wide Range Of Market Segments

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Automotive

Building, Construction and

Infrastructure

Electrical Appliances

Consumer Goods

Packaging

Textile and Carpets

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Applications At A Glance: Building & Construction

Roofing Membranes

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

LyondellBasells thermoplastic polyolefins (TPO) have been specified by

customers 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.

Wire & Cable

Catalloy TPO Resins replacing alternative roofing materials, such as PVC, EPDM and Bitumenmembranes. 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.
Accelerated weathering tests

Flexible Pipes and

Hoses

Durability: more than 20 years of proven

performance

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Aesthetics

Durability

Anti-Tiger stripes

High Softness

Low Gloss

Flexibility

High Clarity

Good Chemical
resistance

Weight reduction

High dimensional
stability

High Filler loading

absorption

Recyclability

Impact/Stiffness Balance

Room & Cold

Temperature Impact

Soft touch

Low shrinkage

Thermal Resistance

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Applications At A Glance: Packaging

Rigid Packaging

Impact Modification with Catalloy Process Resins in Rigid Packaging

Hifax and Adflex resins enhance the performance of rigid and flexible packaging

Industrial 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.

Izod Impact Strength

Flexible Packaging

Room and Cold Temperature Impact

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Aesthetics

Durability

Anti-Tiger stripes

High Softness

Low Gloss

Flexibility

High Clarity

Good Chemical
resistance

Weight reduction

High dimensional
stability

High Filler loading

absorption

Recyclability

Impact/Stiffness Balance

Room & Cold

Temperature Impact

Soft touch

Low shrinkage

Thermal Resistance

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Applications At A Glance: Automotive (I)

Interior

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

Controllable gloss, good aesthetics, grain retention, ductile behavior in impact

tests and low CLTE are typical requirements for components found on the
interior compartment.

Exterior

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.

Under-the-Hood
Note: PP/Elastomer/Talc

Note: PP/Elastomer/Talc

compound including HX X 1956A

compound without HX X 1956A

Flow Marks - Asynchronous Tiger Stripes

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Aesthetics

Durability

Anti-Tiger stripes

High Softness

Low Gloss

Flexibility

High Clarity

Good Chemical
resistance

Weight reduction

High dimensional
stability

High Filler loading

absorption

Recyclability

Impact/Stiffness Balance

Room & Cold

Temperature Impact

Soft touch

Low shrinkage

Thermal Resistance

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Applications At A Glance: Automotive (II)

Interior

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

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

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Aesthetics

Durability

Anti-Tiger stripes

High Softness

Low Gloss

Flexibility

High Clarity

Good Chemical
resistance

Weight reduction

High dimensional
stability

High Filler loading

absorption

Recyclability

Impact/Stiffness Balance

Room & Cold

Temperature Impact

Soft touch

Low shrinkage

Thermal Resistance

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Section III: New Grade Hiflex TPO Resins

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Hiflex TPO Resins- An Innovative Structure

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 LyondellBasells 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)

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Image 1

Conventional Hifax TPO

New Hiflex TPO

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

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

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).

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Hiflex - As Building Block In Your Compounds

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 indepth 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)

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Technical Data Hiflex CA7600A

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

Hiflex TPO Resins in a PP Compound

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Hiflex - Neat Resin Comparison

Handling / Storage

Thermal Properties (DMTA)

Storage Modulus

Glass Transition Temperature (Tg)

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 +/-40C, 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.

Plugged

Plugged

Flowability

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.

Note: C2C8 polyolefin elastomer benchmark based on metallocene catalyst

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Hiflex - Neat Resin Comparison

Chemical Reactivity

Filler Loading Capability

Cross-Linking

Fluidity after high filler loading

Source: Data generated with laboratory scale equipment

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

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.

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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.

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Hiflex Filled and Unfilled PP Compounds

Thermal Properties

Processing
MFR

Spiral

UNFILLED

Vicat Softening Point

FILLED

Method 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.

At similar modification level the compound

based on
Hiflex presents a superior
thermal
resistance
compared
to
compounds based on C2C8 elastomers.

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).

Unfilled Compounds contain LyondellBasells new low emission, high flow homo polymer (Moplen HP500W); Catalloy or C2C8 Modifier and Black Pigmented Masterbatch.
Filled Compounds contain Moplen PP; Catalloy or C2C8 Modifier and 15% Talc.

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Hiflex Filled and Unfilled PP Compounds

Aesthetics

Mechanical Properties
Scratch Resistance

Impact / Stiffness Balance

A significant reduction of gloss in both

unfilled and filled compounds is observed
when modified with Hiflex TPO resins.

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.

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).

FILLED

UNFILLED

Specular Gloss

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Hiflex Great Impact, Stiffness and Shrinkage Balance

Hiflex in a PP Compound
offers:

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

Based 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

Impact, Stiffness and Shrinkage Comparison
Impact @ -20C

*Bubble size corresponds to average shrinkage.

Impact @ -30C

*Bubble size corresponds to average shrinkage.

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

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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 3C/min, 1 Hz

Storage Modulus (DMTA):

Internal Method, 3C/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
Hiflex@lyb.com
Office: +31 (0)10 275 4295
Mobile: +31 (0)653 718062
Vincent Baudier
Application Development Engineer Catalloy
Hiflex@lyb.com
Office: +32 10 81 42 15
Mobile: +32 476 98 26 96
Gisella Biondini
Application Development Engineer Catalloy
Hiflex@lyb.com
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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