MX2007013593A - Cloth-like fiber reinforced polypropylene compositions and method of making thereof - Google Patents

The present invention is directed generally to cloth-like fiber reinforced polypropylene compositions, and the beneficial mechanical and aesthetic properties imparted by such compositions. The cloth-like fiber reinforced polypropylene compositions include at least 25 wt%polypropylene based polymer, from 5 to 60 wt%organic reinforcing fiber, from 0 to 60 wt%inorganic filler, and from 0.1 to 2.5 wt%colorant fiber. A method of making fiber reinforced polypropylene compositions and molding articles there from is also disclosed and includes the steps of twin screw extrusion compounding the composition to form a resin and injection molding the resin to form a cloth-like article. Articles molded from these fiber reinforced polypropylene compositions have a flexural modulus of at least 300,000 psi, exhibit ductilityduring instrumented impact testing, and exhibit a cloth-like appearance. The cloth-like fiber reinforced polypropylene compositions of the present invention are particularly suitable for making molded articles including, but not limited to household appliances, automotive parts, and boat hulls.

POLYPROPYLENE COMPOSITIONS REINFORCED WITH FIBERS SIMILAR TO FABRIC AND METHOD TO FORM THEMSELVES FIELD OF THE INVENTION The present invention is generally directed to articles made of fiber reinforced polypropylene compositions having a flexural modulus of at least 21090 kg / cm2 and exhibiting ductility during the impact of instrumented D test. More particularly, the present invention relates to polypropylene compositions reinforced with fabric-like fibers and processes for forming such articles. Even more particularly, the present invention relates to mixed fiber materials based on polypropylene including a propylene-based polymer, an organic reinforcing fiber, a dye fiber and an inorganic filler.

BACKGROUND OF THE INVENTION Polyolefins have limited use in engineering applications due to the exchange between hardness and ripening. For example, polyethylene is broadly considered to be relatively hard, but low in rigidity.

Polypropylene generally exhibits the opposite tendency, i.e., I is relatively stiff but with low hardness. Several well-known polypropylene compositions have been introduced which provide hardness.

For example, it is known that the increase in hardness of polypropylene by adding rubber particles, either within the reactor :: resulting in impact copolymers or by mixing after the reactor. However, while the hardness is improved, the stiffness is considerably reduced using this approach. Glass-reinforced polypropylene compositions have been introduced to improve stiffness. However, glass fibers have a tendency to force the typical injection molding equipment, resulting in reduced hardness and rigidity. In addition, reinforced vitirio products have a tendency to be wrapped after the model by injection. Another known method for improving the physical properties of polyolefins is the reinforcement of organic fibers. For example, Patent Application EP 0397881, the entire description of which is incorporated herein by reference, discloses a composition produced by melt blending of 100 parts by weight of a polypropylene resin and 10 to 100 parts by weight of polyester fibers having a fiber diameter of 1 to 10 deniers, a length of fibers of 0.5 to 50 mm and a fiber strength I of 5 to 13 g / d, and then molding the resulting mixture, Also, the US Patent 3,639,424 to Gray, Jr. And others, all of which description is incorporated herein by reference, discloses a composition that includes a polymer, such as polypropylene and uniformly dispersed therein by at least about 10% by weight of the base length fiber. , the fiber being man-made polymers such as polyethylene terephthalate or poly (JL, 4-cyclohexylenedimethylene) terephthalate. The fiber reinforced polypropylene compositions are also described in the PCT Publication WO 02/053 29 describes a polymeric compound, which comprises a thermoplastic matrix having a high flux during the melting process and polymer fibers having lengths of 0.1 mm to 50 mm. The polymeric compound comprises between 0.5% by weight and 10% by weight of a lubricant. Various modifications of polypropylene compositions reinforced with organic fibers are also known. For example, polyolefins modified with anhydride or acrylic acid have been used as the matrix component to improve the interfacial strength between the synthetic organic fiber and the polyolefin, which was thought to improve the mechanical properties of the molded product made thereof.

Other background references include PCT Publication O 90/05164; Patent Application EP 066937:.; Patent of E.U.A. No. 6, 395, 342 of Kadowaki et al .; Patent Application EP 1075918; Patent of E.U.A. No. 5, 145, (91 of Yasukawa et al., US Patent 5, 146, 892 of Yasukáwa et al.; and Patent EP 0232522, all descriptions incorporated herein by reference. The Patent of E.U.A. No. 3,304,282, of Cadus et al., Discloses a process for the production of high molecular weight thermoplastics, reinforced with glass fiber in which the plastic resin supplies a continuous extruder or kneader, the endless glass fibers are introduced. in the fusion and they are forced in it, and the mixture is homogenized and discharged through a die. The glass fibers were supplied in the form of endless strands to an injection or degassing port downstream of the feed hopper of the extruder, US Pat. No. 5,401,154 to Sargent discloses an apparatus for forming a thermoplastic material reinforced with fibers and forming parts thereof. The apparatus includes an extruder having a first material inlet, a second material inlet downstream of the first material inlet and an outlet. A thermoplastic resin materilal is supplied in the first material inlet and a first fiber reinforcement material is supplied in the second material inlet of the compounding extruder, which discharges a thermoplastic material reinforced with random fibers melted in the extruder outlet. The fiber reinforcing material may include a bundle of continuous fibers formed of a plurality of single filament fibers. The types of fibers described include glass, carbon, graphite and Kevlar. The Patent of E.U.A. No. 5,595,696 to Schlarb et al. Discloses a mixed plastic fiber and a process for the preparation thereof and more particularly to a mixed material comprising continuous fibers and a plastic matrix. The types of fibers include glass, carbon and natural fibers, and can be fed to the extruder in the form of staple or continuous fibers. The continuous fiber is fed to the extruder downstream of the resin feed hopper. The Patent of E.U.A. No. 6,395,342, Kadowaki et al., Describes an impregnation process for preparing pellets of a polyolefin reinforced with synthetic organic fibers. The process comprises the steps of heating a polyolefin to a temperature that is higher than the melting point thereof by 40 degrees C or more to lower the melting point of a synthetic organic fiber to form a molten polyolefin; passing a reinforcing fiber comprising the synthetic organic fiber continuously through the molten polyolefin within six seconds to form a fiber impregnated with polyolefin, and cutting the impregnated fiber with polyolefin on the pads. Types of organic fibers include polyethylene terephthalate, polybutylene terephthalate, polyamide 6, and polyamide 66. U.S. Pat. No. 6,419,864 to Scheuring et al. Describes a method for preparing filled, modified and fiber reinforced thermoplastics by mixing polymers, additives, fillers and fibers in a twin screw extruder. The continuous fiber strands are fed to the twin screw extruder in a fiber fed zone located downstream of the feed hopper for the polymer resin. The types of fibers described include glass and carbon. The PET fibers feed consistently into a | Compound forming extruder is an aspect encountered during the production of mixed PP-PER fiber materials. Gravimetric or vibrational feeders are used in the measurement and transport of polymers, fillers and additives in the process of forming extrusion compounds. These feeders are designed to transport materials at a constant rate using one or two screws measuring the weight loss in the hopper of the feeder. These feeders are effective for transporting pellets or dust, but are not effective for including ethylene-propylene diene rubber, are incorporated to increase the hardness, either in the polymerization reactor to synthesize an impact copolymer so called, or through mixing. Many interior automotive parts also require a fabric-like appearance and feel. To create such a fabric-like appearance in polypropylene (PP) or thermoplastic olefin (TPO) materials, various fiber-based additives are added to a product of base polymers. Normally the base material has a light gray color and the additives based on fibers have a dark gray or blue color to create a cloth-like effect. However, the presence of these fibers causes a significant decrease in impact properties. To balance the loss of impact resistance, ethylene or -propylene-diene plastomers or rubber (EPDM) are usually added. However, these modifiers also decrease the rigidity (flexi modulus) of the product and substantially increase the cost of raw material. There is a need for a mixed material based on improved polypropylene which gives a combination of high-end aesthetics, impact strength / hardness, and rigidity for use in molded articles at favorable raw material and manufacturing costs. In addition, polypropylene-based mixed material formed in molded articles ideally does not splinter after being broken by impact testing by dropping them under its own weight, and will also have a fabric-like appearance and feel.

SUMMARY OF THE INVENTION Surprisingly it has been found that polypropylene compositions reinforced with fabric-like fibers substantially free of lubricants can be formed which simultaneously have a flexural modulus of at least 21090 kg / cm 2 and exhibit ductility during the instrumented impact test. More particularly, polypropylene compositions reinforced with similar fabric fibers exhibit surprisingly no decrease in impact properties by incorporating dye fiber required to obtain a fabric-like appearance. Even more particularly has the amazing ability to form said! compositions using a wide scale of polypropylene as the matrix material, including some polypropylene that without fiber are very fragile. The compositions of the present invention are particularly suitable for forming articles including, but not limited to, household appliances, automotive parts and boat hulls. In one embodiment, the present invention provides an advantageous polypropylene resin composition comprising, based on the weight total of the composition, at least 30% by weight of polypropylene-based polymer; (b) from 10 to 60% by weight of organic reinforcing fiber; (c) from 0 to 40% by weight of inorganic filler; and (d) from 0.1 to 2.5% by weight of dye fiber; and wherein a molded article of the composition has a flexural modulus of at least 21090 kg / cm2, exhibits ductility during instrumented impact testing, and exhibits a cloth-like appearance. In another embodiment, the present invention provides an advantageous polypropylene resin composition comprising, based on the total weight of the composition, (a) at least 25% by weight polymer based on polypropylene with a melt flow rate from about 20 to about 1500 g / 10 minutes, (b) from 5 to 40% by weight of organic reinforcing fiber; (c) from 10 to 60% by weight of inorganic filler; and (d) from 0.1 to 2.5% by weight of dye fiber; and wherein a molded article of the composition has a flexural modulus of at least about 21090 kg / cm2, exhibits ductility during instrumented impact testing, and exhibits a cloth-like appearance. In yet another embodiment, the present invention provides a composition of advantageous polypropylene resin comprising, based on the total weight of the composition, (a) at least 30% by weight polypropylene-based polymer; (b) from 5 to 40% by weight of organic reinforcing fiber; (c) from 10 to 60% by weight of inorganic filler; and wherein a molded article of the composition has a flexural modulus of at least 21090 kg / cm2, exhibits ductility during the instrumented impact test, and exhibits a cloth-like appearance. In yet another embodiment of the present disclosure provides an advantageous polypropylene resin composition comprising, based on the total weight of the composition, (a) at least 25% by weight polypropylene-based polymer, wherein the The polypropylene-based polymer has a melt flow rate of at least 80 g / 10 minutes (b) from 5 to 15% by weight of organic reinforcing fiber (c) from 50 to 60% by weight of talc or volastonite; and (d) from 0.1 to 1.0% by weight of dye fiber; wherein a molded article of the composition has a flexural modulus of at least about 52725 kg / cm2, exhibits ductility during the instrumented impact test, and exhibits a cloth-like appearance. In still another embodiment of the present description is provided | an advantageous polypropylene resin composition form a resin; and (b) injection molding the resin to form an article. In still another embodiment of the present disclosure, it provides an advantageous method for forming an article of a polypropylene resin composition comprising, based on the total weight of the composition, (a) at least 30% by weight of polymer based on Polypropylene; (b) from 10 to 60% by weight of organic reinforcing fiber; (c) from 0 to 40% by weight dfe inorganic filler; and (d) from 0.1 to 2.5% by weight of dye fiber; wherein the molded article of said LCion composing has a flexural modulus of at least about 21090 kg / cm2, exhibits ductility during instrumented impact testing, and exhibits a cloth-like appearance; and wherein the method comprises the steps of: (feeding the polymer based on polypropylene into a double screw extruder hopper; (b) feeding continuously by unrolling one or more coils into the hopper of the double screw extruder; organic reinforcing fiber; (c) feed in the twin screw extruder the inorganic filler and dye fiber, (d) extrude the resin based on polypropylene, the organic reinforcing fiber, the inorganic filler, and the dye fiber through the twin screw extruder to form a mixed fiber-reinforced polypropylene melt; (e) cool the fiber-reinforced mixed polypropylene melt to form a solid polypropylene composition; and (f) pelletize the polypropylene composition. solid material to form a fiber-reinforced polypropylene resin composition Numerous advantages result from the composite materials of polypropylene fibers similar to advantageous fabrics, the training method described herein and uses / applications thereof. For example, in illustrative embodiments of the present disclosure, the mixed fabric-like polypropylene fiber materials described exhibit improved instrumented impact strength. In a further illustrative embodiment of the present disclosure, the mixed fabric-like polypropylene fiber materials described exhibit improved flexural moduli. In a further illustrative embodiment of the present disclosure, the mixed materials of described cloth-like polypropylene fibers do not splinter during the instrumented impact test. In yet a further illustrative embodiment of the present disclosure, the described fabric-like polypropylene fiber composite materials exhibit fiber traction during instrumented impact testing without the need for lubricating additives.

In yet a further illustrative embodiment of the present disclosure, the described fabric-like polypropylene fiber composite materials exhibit a higher heat distortion temperature compared to hard rubber polypropylene. In yet a further illustrative embodiment of the present disclosure, the mixed fabric-like polypropylene fiber materials described exhibit a lower flow and linear thermal expansion counterflow coefficient compared to hard rubber polypropylene. In yet another illustrative embodiment of the present disclosure, the method described for forming mixed pellets of fiber reinforced polypropylene exhibits the ability to continuously and precisely feed the organic reinforcing fiber into a twin screw compounding extruder, in yet another embodiment Illustrative of the present disclosure, the described method for forming mixed pellets of fiber reinforced polypropylene exhibits the ability of the organic reinforcing fiber to continuously and accurately feed in a double screw compounding extruder, In another illustrative embodiment of the present disclosure, the method described for forming pellets of fiber reinforced polypropylene mixed material exhibits these and other advantages, aspects and attributes of the mixed materials of cloth-like polypropylene fibers and method for creating the present description. and its applications and / or advantageous uses will be evident from the following detailed description, particularly when read together with the figures attached thereto.

BRIEF DESCRIPTION OF THE DRAWINGS To assist those skilled in the relevant art for forming and using the contents thereof, reference is made to the accompanying drawings, wherein Figure 1 describes an illustrative scheme of the method for forming mixed materials of polypropylene reinforced with similar fibers. the present invention. Figure 2 depicts an illustrative scheme of a twin screw extruder with a downstream feed port for forming mixed materials of Dpylene polypropylene reinforced with cloth-like fiber of the present invention. Figure 3 describes an illustrative scheme of a double screw screw extruder configuration for forming polypropylene mixed materials reinforced with cloth-like fiber of the present invention.

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to improved fiber reinforced polypropylene compositions and method for forming same for use in molding applications. The fiber-reinforced polypropylene compositions of the present invention are distinguished from the prior art in that they comprise a combination of a matrix based on Dpylene polypropylene with organic reinforcing fiber and inorganic filler, which in combination advantageously produce articulated molds. compositions with a flexion modulus of at least 21090 kg / cm2 and ductility during instrumented impact testing (24.141 km / hr, -29 ° C, 11.34 kg). The fiber reinforced polypropylene compositions of the present invention can also be distinguished from the prior art since they comprise a polypropylene based polymer with an advantageous high melt flow rate without sacrificing impact strength. In addition [the fiber reinforced polypropylene compositions of the present invention do not splinter during the instrumented impact test. The present invention also relates to polypropylene compositions reinforced with fabric-like fibers, which are distinguished over the prior art by providing a combination of outstanding stiffness, impact resistance, and chip resistance due to impact failure. Fabric-like compositions of the prior art, the polypropylene compositions reinforced with fabric-like fibers of the present invention retain their impact properties in the addition of additives required to impart similar fabric appearance. The polypropylene compositions reinforced with cloth-like fibers of the present invention simultaneously have desirable stiffness, measured having a flexural modulus of at least 21090 kg / cm2, and hardness, measured by the performance exhibited during the instrumented impact test. In a particular embodiment, the compositions have a flexural modulus of at least 24605 kg / cm2, or at least 26011 kg / cm2, or at least 27417 kg / cm2, or at least 28120 kg / cm2, or by at least 31635 kg / cm2. Even more particularly, the compositions have a flexural modulus of at least 42180 kg / cm2 or at least 56240 kg / cm2. It is also thought that having a weak interface between the polypropylene matrix and the fiber contributes to the extracycling of the fiber; and, therefore, can improve the hardness. Therefore, it is not necessary to add modified polypropylenes to improve the bond between the organic reinforcing fiber and the polypropylene matrix, although the use of modified polypropylene may be advantageous to improve the bond between a filler such as talc or volastonite and the matrix | Furthermore, in one embodiment, it is not necessary to add lubricant to weaken the interface between the polypropylene and the organic reinforcing fiber to further improve the extraction of the fibers. Some modalities also exhibit no splintering during the instrumented dart impact test which gives it an additional advantage by not subjecting a person in close proximity to the impact to potentially damaging splintered fragments. The compositions of the present invention include generating at least 30% by weight, based on the total weight of the composition, of polypropylene as the matrix resin In a particular embodiment, the polypropylene is present in an amount of at least 30% by weight, or at least 35% by weight, or by at least 40% by weight, or at least 45% by weight, or at least 50% by weight, or in a quantity within the scale that has a lower limit of % gn weight, or 35% by weight, or 40% by weight or 45% by weight or 50% by weight, or an upper limit of 75% by weight, or 80% by weight, based on the total weight of the composition. In another embodiment, the polypropylene is present in an amount of at least 25% by weight. The polypropylene used as the matrix resin is not particularly resjtring and is generally selected from the group consisting of propylene homopolymers, propylene-ethylene alloy copolymers, random non-olefin propylene copolymers, propylene block copolymers, copolymers of propylene impact, and their combinations. In a particular embodiment, the polypropylene is a propylene homopolymer. In another particular embodiment, the polypropylene is a [propylene impact copolymer comprising from 78 to 95 by weight of homopolypropylene and from 5 to 22% by weight of rubber < (ie ethylene-propylene, based on the total weight of the impact copolymer.) In a particular aspect of this embodiment, the propylene impact copolymer comprises 90 to 95 < % by weight of homopolypropylene and 5 to 10% by weight of ethylene-propylene rubber, based on the total weight of the impact copolymer. The polypropylene of the matrix resin can have a melt flow rate of about 20 to about 1500 g / 10 min. In a particular embodiment, the melt flow rate of the polypropylene matrix resin is greater than 100 g / 10 min, and even more particularly greater than or equal to 400 g / 10 min. In yet another modalipad the melt flow rate of the polypropylene matrix resin is about 1500 g / 10 min. The superior melt flow regime allows for process improvements, performance regimes and superibr load levels of organic reinforcement fiber and inorganic filler without negatively impacting the flexural modulus and impact resistance. In a particular embodiment, the matrix polypropylene contains less than 0.1% by weight of a modifier, based on the total weight of the polypropylene. Normal modifiers include, for example, unsaturated carboxylic acids, such as acrylic acid, methacrylic acid, maleic acid, itaconic acid, fumaric acid or esters thereof, maleic anhydride, itaconic anhydride and derivatives thereof. In another particular embodiment, the Dpylene matrix polyprop does not contain a modifier. In yet another particular embodiment, the polypropylene-based polymer further includes about 0.1% by weight of less than about 10% by weight of a polymer based on polypropylene modified with a grafting agent.

The grafting agent includes, but is not limited to, acrylic acid, methacrylic acid, maleic acid, itaconic acid, fumaric acid or esters thereof, maleic anhydride, itaconic anhydride and combinations thereof. I The polypropylene may further contain additives commonly known in the art, such as dispersant, lubricant, flame retardant, antioxidant, antistatic agent, light stabilizer, ultraviolet light absorber, carbon black, nucleating agent, plasticizer and coloring agent such as coloring or pigmen: o. The amount of additive, if present, in the polypropylene matrix is generally 0.5% by weight or 2.5% by weight, 7.5% by weight, or 10% by weight, based on the total weight of the matrix. The diffusion of the additives during the process can cause a portion of the additives to be present in the organic reinforcing fiber. The invention is not limited by any particular polymerization method to produce the matrix polypropylene and the polymerization processes described herein are not limited by any particular type of reaction vessel. For example, the matrix polypropylene can be produced using any of the well known polymerization processes of slurry polymerization solution, bulk polymerization, gas phase polymerization and combinations thereof. further, the invention is not limited to any particular catalyst to form the polypropylene, and for example, may include :: Ziegler-Natta or metallocene catalysts. The compositions of the present invention generally include at least 10% by weight, based on the total weight of the composition, of an organic reinforcing fiber. In a particular embodiment, the fiber is present in an amount of at least 10% by weight, or at least 15% by weight, p at least 20% by weight, or in an amount within the scale that has a lower limit of 10% by weight, or 15% by weight, or 20% by weight and an upper limit of 50% by weight, D 55 I by weight, or 50% by step or 70% by weight, based on weight total of the composition. In another embodiment, the organic reinforcing fiber is present in an amount of at least 5% by weight and up to 40% by weight. The polymer used as the reinforcing fiber is not particularly restricted and is generally selected from the group consisting of polyalkylene terephthalates, polyalkylene naphthalates, polyamides, polyolefins, polyacylonitrile and combinations thereof. In a particular embodiment, the fiber comprises a polymer selected from the group consisting of polyethylene terephthalate PET), polybutylene terephthalate, polyamide and acrylic. In another particular embodiment, the organic reinforcing fiber comprises PET. In one embodiment, organic reinforcing fiber is a single component fiber. In another embodiment, organic reinforcing fiber is a multi-component fiber where fiber is formed from a process where the fiber is formed from a process where at least two polymers are extruded from separate extruders and blown by melting or centrifuged together to form a fiber. In a particular aspect of this embodiment, the polymers used in the multi-component reinforcing fiber are substantially the same. In another particular aspect of this modalipad, the polymers used in the multi-component reinforcing fiber are different between them. The configuration of the reinforcing fiber of multiple components can be, for example, a cover / cord arrangement, a side-by-side arrangement, a foot arrangement, an arrangement of islands at sea, or a variation from the same. The fiber reinforcement can also be removed to improve mechanical properties via orientation and subsequently anneal at elevated temperatures, but below the crystalline melting point to reduce shrinkage and improve dimensional stability at elevated temperature. The length and diameter of the reinforcing fibers of the present invention are not particularly restricted. In a particular embodiment, the fibers have a length of 6. 35 mm ,. or a length within the scale that has a lower limit of 3,175 mm, or 4 mm, and an upper limit of 7. 62 mm or 12.7 mm. In another particular embodiment, the diameter of the | Reinforcing fibers is within the scale that has a lower limit of 10 pm and an upper limit of 100 pm. The reinforcing fiber may further contain additives commonly known in the art, such as dispersant, lubricant, flame retardant, antioxidant, antistatic agent, light stabilizer, ultraviolet light absorber, carbon black, nucleating agent, plasticizer, and agent. dye such as dye or pigment. The reinforcing fiber used to form the compositions of the present invention is not limited by any particular fiber form. For example, the fiber may be in the form of continuous filament yarn, partially oriented yarn, or basic fiber In another embodiment, the fiber may be a continuous multi-filament fiber or a continuous monofilament fiber. In the present invention, the fiber reinforced polypropylene composition can be made similar to fabric in terms of appearance, feel, or a combination thereof The fabric-like appearance or appearance is defined as having a type of uniform short fibers of surface appearance. The fabric-like feel is defined by having a textured surface or cloth-like feel.The incorporation of the dye fiber into the fiber-reinforced polypropylene composition results in a fabric-like appearance.When the reinforced polypropylene composition of fiber is processed through a mold with a textured surface, a feeling similar to fabric also s and imparts to the surface of the resulting molded part. The polypropylene compositions reinforced with fabric-like fibers of the present invention generally include from about 0.1 to about 2.5% by weight, based on the total weight of the composition of a dye fiber. Even more preferably, the dye fiber is p of about 0.5 to about 1.5% by weight based on the total weight of the composition. Even more preferably, the dye fiber is present in less than about 1.0% by weight based on the total weight of the composition. The type of dye fiber is not particularly restricted and is generally selected from the group consisting of cellulose fiber, fiber acrylic, fiber nylon fiber of the polyester type. Fibers of the polyamide type include, but are not limited to nylon 6, nylon 6,6, rwl with 4,6 and nylon 6,12. In a particular embodiment, the dye fiber is cellulosic fiber, also commonly referred to as rayon. In another particular embodiment, the collorant fiber is a nylon type fiber. The dye fiber used to form the composites of the present invention is not limited by any particular fiber form before being cut for incorporation into the fiber reinforced polypropylene composition. For example, the dye fiber may be in the form of continuous filament yarns, partially oriented yarns, or basic fiber. In another modality, the fiber of titanium, iron oxide, iron hydroxide, chromium oxide, spinel type calcination, chromic talc acid, iron blue chromium vermilion, aluminum powder and bronze powder pigments. These pigments can | be provided in any form or may be submitted in advance for various dispersion treatments in a manner known per se in the art. Depending on the material to be colored, the coloring agent can be added with one or more of various additives such as organic solvents, resins, flame retardants, antioxidants, ultraviolet absorbers, plasticizers and surfactants. The mixed material of polypropylene reinforced with base fibers in which the coloring fiber is incorporated can also be colored using the inorganic pigments, organic dyes or their combinations. The illustrative pigments and dyes for the mixed polypropylene material reinforced with base fibers can be of the same type as indicated in the preceding paragraph for the dye fiber. Normally the mixed polypropylene material reinforced with base fibers is made of a different color or a different shade of color than the fiber of dyes, in such a way that it creates a fabric-like appearance by uniformly dispersing the fibers of short dyes in the material mixed polypropylene reinforced with colored base fibers. In a particular illustrative embodiment, the mixed material of polypropylene reinforced with base fibers is light gray in color and the dye fiber is of a dark gray or blue color to create a fabric-like appearance of the | addition of short dye fiber uniformly dispersed through mixed polypropylene material reinforced with base fiber, dye fiber in a cut fiber form can be incorporated directly into the mixed material of polypropylene reinforced with base fiber via the process of Formation of double screw extrusion compounds or can be incorporated as part of a masterbatch resin to further facilitate the dispersion of the dentrq dye fiber of the mixed fiber-reinforced polypropylene base material. When the colorant fiber is incorporated as part of a master batch resin, illustrative vehicle resins include, but are not limited to, polypropylene homopolymer, ethylene-propylene copolymer, ethylene-propylene-butene-1 terpolymer, copolymer propylene-butenq-1, low density polyethylene, high density polyethylene and linear low density polyethylene. In an illustrative embodiment, the dye fiber is incorporated into the carrier resin at less than about 25% by weight. The masterbatch of the dye fiber is then incorporated into the mixed fiber-reinforced polypropylene base material at a loading of about 1% by weight OR about 10% by weight, and preferably from about 2 to about 6% by weight. In a particularly preferred embodiment, the master lot of collorant fiber is added to approximately 4% by weight based on | total weight of the composition. In another illustrative embodiment, a masterbatch of black rayon or black nylon type fibers in linear low density polyethylene vehicle resin is incorporated at a loading of about 4% by weight in the reinforced polypropylene mixed base material, the dye fiber or colorahte fiber master batch can be fed to the process of forming double screw extrusion compounds with a gravimetric feeder in the feed hopper or in a feed port downstream of the twin screw extruder. The knitting and mixing elements are incorporated into the twin screw extruder screw design downstream of the dye fiber injection point or dye fiber masterbatch, so as to uniformly disperse the dye fiber within the mixed polypropylene material reinforced with fabric-like dye fiber. The compositions of the present invention optionally include inorganic filler in an amount of at least L% by weight, or at least 5% by weight, or at least 10% eh, or in an amount within the scale having a lower limit of 0% by weight, or 1% by weight, or 5% by weight, or 10% by weight, 15% by weight and an upper limit of 25% by weight, or 30% by weight, or 35% by weight or 40% by weight, based on the total weight of the composition. In yet another embodiment, the inorganic filler may be included in the mixed polypropylene fiber material in the range of 120% Jpeso to about 60% by weight. In a particulate embodiment, the inorganic filler is selected from the group consisting of talc, calcium carbonate, calcium hydroxide., barium sulfate, mica, calcium silicate, clay, kaolin, silica alumina, volastonite, magnesium carbonate, magnesium hydroxide, titanium oxide, zinc oxide, zinc sulfat, and combinations thereof. The talc can (have a size of about 1 to about 100 microns) In a particular embodiment, a high talc load of up to about 60% by weight, the mixed polypropylene fiber material exhibited a flexural modulus of at least approximately 52725 kg / cm2, and does not splinter during the instrumented impact test (15 rph, -29 ° C, 11.34 kg) In another particular mode, at a low talc load of so much as 10% by weight, the mixed material of polypropylene fibers exhibited a flexural modulus of at least about 22847.5 kg / cm2 and did not splinter during the instrumented impact test (15 rph, -29 ° C, 11.34 kg). % by weight to 60% by weight qn the mixed polypropylene fiber material gave an outstanding eminency of impact resistance and rigidity In another particular embodiment, a polypropylene reinforced composition with fabric-like fiber includes a resin based on polypropylene with a melt flow rate of 80 to 1500, 10 to 15% by weight of polyester fiber and 50 to 60% by weight of the inorganic filler exhibited a flexural modulus of 59755 to 84360 kg / cm2 and not It is destroyed during the instrumented impact test at -20 degrees Celsius, tested at 11.34 kg and 6.706 M / sec. The inorganic filler includes, but is not limited to, talc and volatite nita This combination of stiffness and hardness is difficult to use in a polymer-based material. In addition, the fiber-reinforced polypropylene composition has a heat distortion temperature of 4.64 kg / cm2 of 140 degrees centigrade and a coefficient of flow and counterflow of linear thermal expansion of 2.2 x 10"5 and 3.3 x 10 ~ 5 per In contrast, rubber-hardened polypropylene has a heat distortion temperature of 94.6 degrees centigrade and a coefficient of thermal expansion of flow and counterflow of 10 x 10 and 18.6 x 10"$ per degree centigrade respectively.

The fabric-like fiber reinforced polypropylene compositions of the present invention give an advantageous combination of hardness, stiffness and aesthetics. In particular, the instrumented impact of molded articles is not | affects negatively by the incorporation of fiber dyes. In addition, the failure mode during the instrumented impact test is ductile (n splinter) as opposed to fragile] (splinter). Articles made from the compositions described herein include, but are not limited to automotive parts, household appliances and boat helmets. Fabric-like articles are particularly suitable for interior automotive parts due to the unique combination of hardness, rigidity and aesthetics. More particularly, the non-splinter nature of the failure mode during the instrumented impact test, and the fabric-like appearance made of the reinforced, fabric-like polypropylene reinforced materials of the present invention particularly suitable for automotive interior parts, even more particularly suitable for Cut-out panels include: steering wheel covers, top-lining panels, dash panels, cut-out panels for interior doors, roof panels cut from columns and bottom panel panels. The panels of cut roofs of columns include a roof panel cut from front columns, a roof panel cut from central columns and a roof panel cut from fourth parts of columns. The articles of the present invention are made by forming the polypropylene composition reinforced with fabric-like fibers in a resin and then injection molding the resin composition to form the article. PPaarraa ll | ooggrar a fabric-like surface feel in the article the surface of the mold can also have a textured surface. The invention is not limited to any particular method for forming the compositions. For example, the compositions can be formed by contacting the polypropylene, organic reinforcing fiber, dye fiber and optional inorganic filler in any of the well-known processes of compounding by pultrusion or extrusion. In a particular embodiment, the compositions are formed in a process of forming compounds by extrusion. In a particular aspect of this embodiment, the organic reinforcing fibers are cut before being placed on the extruder tollva. In another particular aspect of this embodiment, the organic reinforcing fibers are fed directly from one or more coils into the extruder hopper. Figure 1 depicts an illustrative scheme of processing to form the reinforced polypropylene composite materials of cloth-like fibers of the present invention. The resin based on polypropylene 10, inorganic filler 12, dye fiber 13, and organic reinforcing fiber 14 continuously unrolled from one or more coils 16 are fed into the extruder hopper 18 of a twin screw compounding extruder 20. The dye fiber 13 preferably has the form of a masterbatch resin. The extruder hopper 18 is positioned above the throat of the feeder 19 of the screw compounding extruder 20. The hopper of the extruder 18 can alternatively be provided with a drill (not shown) for mixing the polypropylene-based resin 10 and the filler. inorganic 12 before introducing it into the feed throat 19 of the twin screw compounding extruder 20. In an alternative embodiment, as described in Figure 2, the inorganic filler 12 and / or the dye fiber 13 can be fed to the double screw compounding extruder 20 in a downstream feed port 27 in the barrel of the extruder 26 positioned downstream of the extruder hopper 18 while the polypropylene-based resin 10 and the organic reinforcement fiber 1 are still measured in the hopper of the extruder 18. The resin based on polypropylene 10 is introduced into the hopper of the extruder 18 via a feed system 30 to control precisely the diet. Simila :: mind, the inorganic filler 12 and the fiber coil fiber 16 that are unwound simultaneously and the rotations per minute of the extruder. The twin-screw compounding extruder 20 includes a drive motor 22, a gearbox 24, an extruder barrel 26 for containing two screws (not shown), and a wire die 28. The barrel of the extruder 26 segmented in a number of hot controlled temperature zones 28. As described in Figure 1, the barrel of the extruder 26 includes a total of ten temperature control zones 28. The two screws inside the barrel of the extruder 26 of the extruder of The formation of double-screw compounds 20 can be interspersed or non-intercalated and can rotate in the same direction (co-rotandb) or rotate in opposite directions (counter-rotating).

From a processing view, the melting temperature should be maintained above the polypropylene-based resin 10, and well below the melting temperature of the organic reinforcing fiber 14, so that the mechanical properties imparted by the organic fiber it will be maintained when mixed in the polypropylene-based resin 10. In an illustrative embodiment, the barrel temperature of the extruder zones does not exceed 154 ° C when the homopolymer PP and the PET fiber are extruded, which gave a melting temperature above the melting point of the homopolymer of PP, but well below the melting point of the PET fiber. In another illustrative embodiment, the barrel temperatures of the extruder zones are set at 185 ° C or lower. An illustrative scheme of a screw configuration of the twin-screw compounding extruder 20 to form mixed fiber-reinforced polypropylene materials is described in Figure 2. The feed garget 19 allows the introduction of polypropylene-based resin, fiber organic reinforcement, dye fiber and inorganic filler in a feed zone of the double screw composite forming extruder 20. The inorganic filler and dye fiber can optionally be fed to the extruder 20 in the downstream feed port 27. The double screws 30 include an arrangement of the interconnected screw sections, including conveying elements 32 and kneading elements 34. The kneading elements 34 function to melt the polypropylene-based resin, longitudinally cut the organic reinforcing fibers and mix the polypropylene-based melt. , the organic reinforced fiber cut , dye fiber and inorganic filler to form a uniform mixture. More particularly, the kneading elements work to break | the organic reinforcing fiber in fiber lengths of about 3.175 mm to about 2.54 mm. A series of interconnected kneading elements 34 are also referred to as a kneading block. The Patent of E.U.A. No. 4,824,256 to Haring, et al., Incorporated herein by reference in its entirety, describes co-rotating double screw extruders with kneading elements. The first section of kneading elements 34 located downstream of the feed throat is also referred to as the melting zone of the twin screw compounding extruder 20. The conveyor elements 32 function to transport the solid components, melt the resin based in polypropylene, and transporting the polymer melt mixture based on polypropylene, inorganic filler, dye fiber and organic reinforcing fiber downstream to the strand die 28 (see Figure 1) at a positive pressure. The position of each of the screw sections as expressed in the number of diameters (D) from the start 36 of the screws of the extruder 30 are also described in Figure 3. The screws of the extruder in Figure 3 have a relationship from length to diameter of 40/1, and in a position 32D of the start 36 of the screws 30, a kneading element 34 is placed. The particular arrangement of the kneading or transporting sections is not limited to that described in Figure 3, however, one or more kneading blocks consisting of an array of interconnected kneading members 34 may be placed on the double screws 30 at a point downstream where the organic fiber and the inorganic filler are introduced into the extruder barrel. The double screws 30 can have an equal screw length or unequal screw length. Other mixing section sites may also be included in the double 30 screws, including, but not limited to, Maddock mixers, and bolt mixers. Referring again to Figure 1, the mixed blend of uniformly blended fiber-reinforced polypropylene comprising polypropylene-based polymer., inorganic filler 12, dye fiber 13, and organic reinforcing fiber 14 is measured by the screws of the extruder to a die of strand 28 to form one or more continuous strands 40 of mixed fiber-reinforced polypropylene melt. One or more continuous strands 40 are then passed in water bath 42 to cool them below the melting point of the mixed fiber-reinforced polypropylene melt to form strands of polypropylene mixed material reinforced with solid fibers 44. The water bath 42 normally It cools and controls at a constant temperature well below the melting point of the polypropylene-based polymer :. The strands of polypropylene mixed material reinforced with solid fibers 44 are then passed in a pelletizer or pelletizing unit to be cut into mixed polypropylene resin material reinforced with fibers 48 measuring from about 6.35 mm to about 2.54 m in length . The fiber-reinforced polypropylene mixed material resin 48 can then be stored in boxes 50, barrels, or alternatively transported in silos for storage. The present invention is further illustrated by means of the following examples and the advantages thereof without limiting the scope thereof.

Test Methods Polypropylene compositions reinforced with fibers! described here were molded by injection at a pressure of 161.69 kg / cm2, 401 ° C to all zones! of heating as well as the nozzle, with a mold temperature of 60 ° C. Bending module data was generated for injected molded samples produced from the fiber reinforced polypropylene compositions described herein using the standard ISO 178 method. The instrumented impact test data was generated for injected mold samples produced from the fiber reinforced polypropylene compositions described herein using ASTM D3763. The ductility during Cimpact CB7 is a modified talc on its surface and V383. { 7 is a talc with high aspect ratio, available from Luzenac America Inc. of Englewood, Colorado. Granita Fleck is a master batch of dark polyimel fiber in a linear low density carrier resin and is commercially available from Uniform Color Companj / of Holland, Michigan.

Illustrative examples 1-8 Variable amounts of PP3505G and 6.35 mm long polyester reinforcing fibers obtained from Invistat Corporation were mixed where they were mixed in an Isolo Haake screw extruder at 175 ° C. The strand exiting the extrusion was cut into 12.7 mm lengths and injection molded using a Boy injection moulder of 45.3 kg at 205 ° C in a mold maintained at 60 ° C. Injection pressures and nozzle pressures were maintained at 161.69 kg.

The mulestras were molded according to the geometry of ASTM D3763 and tested for instrumented impact under normal automotive conditions for interior parts (11.34 | kg, at 24.141 km / hr, at -29 ° C). The total results of absorbed energy of impact are given in Table 1.

Table 1 * Ejeijiplos 1-6: the samples do not splinter or divide as a result of the impact, without pieces of the specimen coming out ** Example 7: the pieces are separated from the sample as a result of the impact, example 8: the samples are completely splintered as a result of the impact.

Illustrative Examples 9-14 In Examples 9-11, 35% by weight of PP7805, 20% by weight of Cimpact CB7 talc, and 45% by weight of 6.35 mm long polyether reinforcing fibers from Invista Corporation, mixed in a Haakel twin-screw extruder at 175 ° C. The strand exiting the extruder was cut into 12.7 mm lengths and injection molded using a Boy injection moulder of 49985.618 kg at 205 ° C in a mold maintained at 60 ° C. The injection pressures and * Examples 9-1: the samples were not splintered or divided as a result of impact, without specimen parts being loosened. ** Examples 13-14: Samples were splintered as a result of impact.

Illustrative examples 15-16 A Leistritz ZSE27 27 mm twin-screw extruder HP-60D with a length-to-diameter ratio of 40: 1 was adapted with six pairs of 30.48 cm kneading elements from the die outlet. The die was 6.35 mm in diameter. Threads of 27,300 denier PET reinforcement fibers were fed directly from the coils into the extruder hopper, along with PP7805 and talcum. The kneading elements in the extruder separated the reinforcement fiber in situ. The speed of the extruder was 400 revolutions per minutol and the temperatures through the extruder were maintained at 190 ° C. Injection molding was performed under conditions similar to those described for Examples 1-14. The mechanical and physical properties of the sample were measured and compared in Table 3 with the mechanical and physical properties of PP8224 The instrumented impact test showed that in both examples there was no evidence of division or chipping, without the pieces being come out of the specimen. In the notched Charpy test, the specimen of PP7805 reinforced with PET fibers only partially separated and specimen PP8224 separated | completely.

Table 3 Illustrative Examples 17-18 In Examples 17-18, 30% by weight of PP3505G or PP8224, 15% by weight of 6.35 irm long polyester reinforced fibers obtained from Invista Corporation, and 45% by weight of talc V3837 were mixed in a Haake twin screw extruder at 175 ° C. The strand exiting the extruder was cut into 12.7 mm lengths and injection molded using a Boy injection m-tool of 49985.618 kg at 205 ° C in a mold | maintained at 60 ° C. The injection pressures and nozzle pressures were maintained at 161.69 kg / cm3. The samples were molded according to the geometry of ASTM D3763 | and tested for flexural modulus. The results of the flexural modulus are given in Table 4.

Table 4 The PP8114 matrix hardened with rubber with PET and talc reinforcing fibers exhibited lower impact values than PP3505 homopolymer. This result is surprising, because the rubber-hardened matrix alone is much harder than the low molecular weight PP3505 homopolymer only at all temperatures under any impact condition. In both previous examples, the materials did not exhibit chipping.

Illustrative examples 19-2 In Examples 19-24, 25-75% by weight PP3505G, 15% by weight of 6.35 mm polyester reinforcement fibers I obtained from Invista Corporation, and 10-60% by weight talc I V3837 mixed in the Haake twin screw extruder | at 175 ° C. The strand exiting the extruder was cut into 12.7 mm lengths and injection molded using a Boy injection moulder of 49985.618 kg at 205 ° C in a mold maintained at 60 ° C. The injection pressures and nozzle pressures were maintained at 161.69 kg / cm2. The samples were molded according to the geometry of AST D3763 and tested for flexural modulus. The results of the flexural modulus are given in Table 5.

Table 5 It is important to note that in Examples 19-24, the samples did not exhibit chipping in the weight drop test at -29 ° C, 24,141 km / hr at 11.34 kg.

Illustrative Examples 25-26 Two materials, one containing 10% polyester reinforcing fibers of 6.35 mm, 35% of polypropylene PP3505 and 60% (of talc V3837 (example 25), the other containing 10% of reinforcing fibers of 6.35 mm polyester, 25% PP3505 polypropylene homopoLimer (example 26), 10% modified PO1020 polypropylene were molded in a Haake screw extruder at 175 ° C. They were molded by inlyecc® into tensile specimens of the AST A370 normal width 12.7 mm blade type The specimens were tested in tension, with a minimum to maximum load ratio of 0.1, in bending tensions of 70 and 80% of the maximum tension.

Table 6 The addition of the modified polypropylene is shown to increase the fatigue life of these materials.

Illustrative examples 27-29 A Leistrjitz 27mm co-rotator twin screw extruder with a length-to-diameter ratio of 40: 1 was used in | these experiments. The process configuration used was described in Figure 1. The screw configuration used was described in Figure 3, and includes an arrangement of transport and kneading elements. Talc, polypropylene and PET reinforcement fiber were fed into the feed hopper of the extruder located approximately two diameters from the start of the extruder screws (19 in Figure 3). The PET reinforcement fiber was fed into the extruder hopper by continuously feeding a fiber tow of 3100 filaments from each hopper, each filament having a denier of about 7.1. Each filament was 27 microns in diameter, with a specific gravity of 1.38. The twin screw extruder ran at 603 rotations per minute. Using two gravimetric feeders, polypropylene PP7805 was fed into the extruder hopper at a rate of 9 kg / hour, while talc CB7 was fed into the extruder hopper at a rate of 6.8 kg / hour PET reinforcement fiber was fed in the extrusion at 5.4 kg / hour, which was dictated by the speed of the screw and the thickness of the tow. The temperature profile of extruspr for the ten zones 144 ° C for zones 1-3, 133 ° C for zone 154 ° C for zone 5, 135 ° C for zone 6, 123 ° C for zones 7-9, and 13 ° C for zone 10. The die diameter of the strand at the exit of the extruder was 6.35 mm. The extrudate was cooled in a water depression of 2. 4 meters long and formed into pellets at a length of 12.7 mm to form mixed PET / PP pellets. The extrudate exhibited uniform diameter and could easily be pulled through the cooling bath without ruptures in the water bath b during the instrumented impact test. The durantje the formation of extrusion compounds so that the mixed PET / PP resin had poor instrumented impact test properties. In Example 29, the fiber was fed into a hopper placed 14 diameters under the extruder (27 in Figure 3). In this case, the extrudate produced was of irregular diameter and broke to an average once every minute since it was extracted through the cooling water bath.

When PET fiber reinforcing tow was continuously fed downstream of the extruder hopper, PET dispersion in the PP matrix was negatively impacted from the mason that a uniform extrusion could not occur, resulting in irregular diameter and breakage of the extrusion. extruded Illustrative Example 30 An extruder with the same size and screw design was used as in examples 27-29. All extruder zones were initially heated to 180 ° C. PP 3505 was mixed dry with Jetfine 700 C and PO 1020 was fed at 22.6 kg / hour using a gravimetric feeder in the extruder tank located approximately two diameters from the start of the extruder screws. The polyester fiber with a denier of 7.1 and a thickness of 3100 ilaments was fed through the same hopper. The screw speed of the extruder was adjusted to 596 revolutions per minute, resulting in a feed rate of 5.4 kg of fiber per hour. After a uniform extrudate was obtained, all temperature zones were lowered to 120 ° C, and the extrudate formed into pellets after temperatures were reached in the resting state. The final composition of the mixture was 48% PP 3505, 29.1% Jetfine 700 ° C, 8.6% PO 1020 and 14.3% polyester reinforcing fiber. The mixed PP resin produced while all extruder temperature zones adjusted to 120 ° C were injection molded and exhibited the following properties: Table 8 Example 30 Module Jie Flexion, Load @ 23 ° C 32895.62 Kg / cm2 Impact Instrumented @ 23 ° C 8.0 J D ** Impact Instrumented @ -30 ° C 10.4 J D ** ** Fai: a ductile with radial cracks Illustrative Examples 31-34 4% Granita Fleck, which is a master batch of dark polyester fiber in a low density polyethylene carrier resin, was compounded by extrusion with a twin screw extruder in impact copolymer based on polypropylene ( PP 8114) (control sample) and also in a PP / PET fiber / talc homopolymer blend (40% PP3505G polypropylene, 15% Invista PET reinforcement fiber (6.35 mm length) and 41% Luzenac Jetfine talc 3CA ) (embodiment of the present invention). The corresponding resin samples in the masterbatch incorporation of dye fibers (without Granita Fleck) were also produced to evaluate the impact of the dye fiber on impact properties for the PP impact copolymer of the prior art and the mixed material reinforced PP-PET fiber of the present invention. The fiber-reinforced polypropylene composite material without the dye fiber included 40% polypropylene PP3505G, 15% PE reinforcement fiber Inv Invista (length of 6.32 mm), and 45% talc Luzenac JetfiHe 3CA. These four resin samples were molded according to the geometry of ASTM D3763 and tested for resistance to instrumented impact and failure mode due to impact failure. The results of the instrumented impact test are given in Table 9.

Table 9 From Table 9, it is important to note that by incorporating the dye fiber into the impact polymer (Example 32) of the prior art, there is a decrease of about 88% in instrumented impact resistance and also the failure mode going from ductile (without division) to fragile (with division). By contrast, when the dye fiber is added to the PP / PET fiber / talc composition material (Example 349 of the present invention, there is no decrease in instrumented impact resistance, while the failure mode remains ductile in nature, with reduction intangible in flexural modulus The mixed material PP / PET fiber / dye fiber after molding also has a fabric-like appearance from the incorporation of the dark dye fiber dispersed evenly throughout the molded object. blended PP / PET fiber / dye fiber (Example 34) retains its outstanding impact strength unlike the rubber modified PP impact copolymer / dye fiber sample of the prior art (Example 32). patents, test procedures and other documents cited in the present, including priority documents, are fully incorporated by reference to the extent that said description is not inconsistent with this invention and for all jurisdictions in which incorporation is permitted. While the illustrative embodiments of the invention have been described with particularity, it will be understood that various other modifications will be apparent and can easily be made by those skilled in the art without departing from the spirit and scope of the invention. Accordingly, it is not intended that the scope of the claims appended thereto be limited to the examples and descriptions set forth herein but that the claims be construed as encompassing all aspects of patentable nov ... age residing in the invention, including all aspects that could be treated as equivalents of the milsmas by the experts in the matter to which the invitation belongs. When the numerical lower limits and numerical upper limits are listed here, variations of any limit lower than any limit are contemplated! higher .

1. CLAIMS 1. - A polypropylene resin composition comprising: (a) at least 30% by weight, based on the total weight of the composition, polypropylene-based polymer; (b) from 10 to 60% by weight, based on the total weight of the composition, organic reinforcing fiber, (c) from 0 to 40% by weight, based on the total weight of the composition, inorganic filler; and (d) from 0.1 to 2.5% by weight, based on the total weight of the composition, dye fiber; wherein a molded article of said composition has a flexural modulus of at least 21090 kg / cm 2, exhibits ductility during the instrumented impact test, and exhibits a cloth-like appearance. 2. - The polypropylene resin composition of claim 1, wherein said polypropylene-based polymer is selected from the group consisting of polypropylene homopolymers, random proprietary copolymers of Leno-ethylene, random copolymers of propylene-to-olefia, copolymers impact of propylene and its combi ations. selects from the group consisting of talcum, calcium carbonate, calcium hydroxide, barium sulfate, mica, calcium silicate, clay, kaolin, silica, alumina, volastonite, magnesium carbonate, magnesium hydroxide, titanium oxide, zinc, zinc sulfate, and their combinations 9. - The polypropylene resin composition of claim 8, wherein the inorganic filler is talc or volastonite 10. - The polypropylene resin composition of claim 5, wherein the dye fiber includes an inorganic pigment, an organic dye, or a combination thereof. 11. The polypropylene resin composition of claim 10, wherein said dye fiber is selected from the group consisting of cellulosic fiber, acrylic fiber, nylon type fiber, polyester type fiber. and its combinations. 12. - The polypropylene resin composition of claim 11, wherein said dye fiber is from about 0.78 mm to about 6.35 mm in length, 13. The polypropylene resin composition of claim 12, wherein the Polypropylene-based polymer further comprises an inorganic pigment, an organic colorant, or a combination thereof. olefin, propylene impact copolymers and their combinations. 17. - The polypropylene resin composition of claim 16, wherein said polypropylene-based polymer is polypropylene homopolymer with a melt flow rate of about 150 to about 1500 g / 10 rrnutes. 18. - The polypropylene resin composition of claim 15, wherein said polypropylene-based polymer further comprises about 0.1% by weight less than about 10% by weight of a polymer based on polypropylene modified with a grafting agent, in wherein said grafting agent is selected from the group consisting of acrylic acid, methacrylic acid, maleic acid, itaconic acid, fumaric acid or ethers thereof, maleic anhydride, itaconic anhydride and combinations thereof. 19. - The polypropylene resin composition of claim 15, wherein said organic reinforcing fiber and said dye fiber are randomly dispersed within said polypropylene-based polymer. 20. - The polypropylene resin composition of claim 19, wherein said organic reinforcing fiber is selected from the group consisting of po-jialkylene terephthalates, polyalkylene naphthalates, polyamides, polyolefins, polyacrylonitrile, and combinations thereof. 21. - The polypropylene resin composition of claim 20 wherein said organo-reinforcing fiber is polyethylene terephthalate at a loading of about 7.5% to about 20% by weight. 22. - The polypropylene resin composition of claim 15, wherein said inorganic filler is selected from the group consisting of talc, calcium carbonate., calcium hydroxide, barium sulfate, mica, ca. clay, kaolin, silica, alumina, volastonite, magnesium carbonkto, magnesium hydroxide, titanium oxide, zinc oxide, zinc sulfate and their combinations. 23. - The polypropylene resin composition of claim 22, wherein said inorganic filler is talc or volastonite at a loading of about 20% to about 60% by weight. 24. - The polypropylene resin composition of claim 23, wherein the size of said talc is from about 1 to about 100 microns. 25. - The polypropylene resin composition of claim 19, wherein said dye fiber includes an inorganic pigment, an organic dye or a combination thereof. I 26. - The polypropylene resin composition of claim 25, wherein said dye fiber is selected from the group consisting of cellulosic fiber, acrylic fiber, nylon type fiber, polyester type fiber and combinations thereof. 27. - The polypropylene resin composition of claim 21, wherein said dye fiber is from about 0.762 mm to about 3.175 mm in length. 28. - The polypropylene resin composition of claim 27, wherein said polypropylene-based polymer further comprises an inorganic pigment an organic dye or a combination thereof, 29. - The polypropylene resin composition of claim 28, wherein said molded article of said composition has a flexural modulus of at least about 42180 kg / cm2. 30. - The polypropylene resin composition of claim 29, wherein said molded article of said composition has a flexural modulus of at least about 70300 kg / cm2. 31. A polypropylene resin composition comprising: a) at least 30% by weight, based on the total weight of the composition, polypropylene-based polymer; (b) from 5 to 40% by weight, based on the total weight of the composition, organic reinforcing fiber, (c) from 10 to 60% by weight, based on the total weight of the composition, inorganic filler; (d) from 0.01 to 0.1% by weight, based on the total weight of the composition, lubricant; and (e) from 0.1 to 1.0% by weight, based on the total weight of the composition, dye fiber; wherein a molded article of said composition has a flexural modulus of at least 21090 kg / cm2, exhibits ductility during the instrumented impact test, and exhits a cloth-like appearance. 32. The polypropylene resin composition of claim 31, wherein said lubricant is selected from the group consisting of silicone oil, silicone gum, amide tjrase, paraffin oil, paraffin wax and ester oil 33. - The polypropylene resin composition of claim 31, wherein said polymer based on polypropylene is polypropylene homopolymer. 34. - The polypropylene resin composition of claim 31, wherein said organically reinforcing fiber and said dye fiber is randomly dispersed within said polypropylene-based polymer. wherein said polypropylene-based polymer has a melt flow rate of at least 80 g / 10 minutes; (b) from 5 to 15% by weight, based on the total weight of the composition, organic reinforcing fiber, (c) from 50 to 60% by weight, based on the total weight of the composition, inorganic filler; and (e) from 0.1 to 1.0% by weight, based on the total weight of the composition, dye fiber; wherein a molded article of said composition has a flexural modulus of at least 52725 kg / cm 2, exhibits ductility during the instrumented impact test, and exhibits a cloth-like appearance. 42. - The polypropylene resin composition of claim 41, wherein said polypropylene-based polymer is polypropylene homopolymer with a melt flow rate of at least about 400 g / 10 minutes. 43. - The polypropylene resin composition of claim 41, wherein said polypropylene-based polymer further comprises from about 0.1% to less than about 10% by weight of a polypropylene-based polymer modified with a grafting agent, in where grafting agent is selected from the group consisting of acrylic acid, methacrylic acid, maleic acid, litaconic acid, fumaric acid or esters thereof, maleic anhydride, itaconic anhydride and combinations thereof, 44. - The polypropylene resin composition of Re: v. 41, wherein said reinforcing fiber and said dye fiber are randomly dispersed within the polypropylene-based polymer. 45. - The polypropylene resin composition of claim 44, wherein the organic reinforcing fiber is polyethylene terephthalate. 46. - The polypropylene resin composition of claim 44, wherein the dye fiber includes an inorganic pigment, an organic dye or a combination thereof. 47. - The polypropylene resin composition of claim 46, wherein the dye fiber is selected from the group consisting of cellulosic fiber, acrylic fiber, or nylon type fiber. 48. - The polypropylene resin composition of claim 47, wherein the polypropylene-based polymer further comprises an inorganic pigment, an organic dye or a combination thereof 49. - The polypropylene resin composition of claim 48, wherein said molded article of the composition has a flexural modulus of at least about 70300 kg / cm2 A polypropylene resin composition which A polypropylene resin composition comprising: (a) at least 40% by weight, based on the total weight of the polypropylene-based polymer composition, wherein said polypropylene-based polymer has a flux or melt flow rate. at least 100 g / 10 minutes; (b) from 10 to 30% by weight, based on the total weight of the composition, organic reinforcing fiber, (c) from 10 to 30% by weight, based on the total weight of the composition, inorganic filler; and | e) from 0.1 to 1.0% by weight, based on the total weight of the bombardment, dye fiber; wherein a molded article of said composition has | a flexural modulus of at least 22847.5 kg / cm2, exhibits ductility during the instrumented impact test, and exhibits a cloth-like appearance. 51.- The polypropylene resin composition of claim 50, wherein the polypropylene-based polymer is polypropylene homopolymer with a melt flow rate of at least about 400 g / 10 min. 52.- The resin composition of polypropylene of claim 50, wherein said polypropylene-based polymer further comprises about 0.1% polypropylene further comprising an inorganic pigment, an organic dye, or a combination thereof. 58. - The polypropylene resin composition of claim 57, wherein said molded article of said composition has a flexural modulus of at least about 26362.5 kg / cm2. 59. A method for forming an article of a polypropylene resin composition comprising: a) at least 30% by weight based on the total weight < } ie the composition, polymer based on polypropylene; (b) from 10 to 60% by weight, based on the total weight of the composition, organic reinforcing fiber; c) from 0 to 40% by weight, based on the total weight of the composition, inorganic filler; and (d) from 0.1 to 2.5% by weight based on the total weight of the composition, dye fiber; wherein said molded article of said composition has a flexural modulus of at least 21090 kg / cm2, exhibits ductility during instrumented impact testing, and exhibits a cloth-like appearance; wherein the method comprises the steps of: a) forming into compounds by double screw extrusion & said composition to form a resin; and (b) injection molding said resin to form an article 60. - The method of claim 59, wherein the step of injection molding further comprises the step of providing a mold with a textured surface, wherein the articu (Lo exhibits in addition a cloth-like feel, 61. - The method of claim 59, wherein the organic reinforcement fiber I is cut before the step of forming compounds by double screw extrusion 62. The method of claim 59, wherein during the step of forming extrusion compounds of double screw, the organic fiber is a continuous fiber and is fed directly from one or more coils in a hopper of the ds extruder type 63. - An automotive part made by the method of claim 59, 64.- The automotive part of the Claim 63, wherein said automotive part is an interior cut-out panel selected from the group consisting of a rotating wheel cover, an upper liner panel, a panel panel, a panel cut from inner door, a cut-off column panel, and an inferior board panel. 65.- A method for forming a fiber reinforced polypropylene resin composition comprising: (a) at least 25% by weight based on the total weight of the composition, polypropylene based polymer with (e) cooling the mixed fiber reinforced polypropylene melt to form a solid polypropylene composition; and (f) pelletizing said solid polypropylene composition to form a reinforced polypropylene resin composition. 66. - The method of claim 65, wherein the polypropylene-based resin is selected from the group consisting of polypropylene homopolymers, random propylene-ethylene copolymers, random non-ot-olefin propylene copolymers, propylene impact copolymers, and combinations thereof. 67. - The method of claim 66, wherein the polypropylene based resin is polypropylene homopolymer with a melt flow rate of about 150 to about 1500 g / 10 minutes. 68. - The method of claim 65, wherein the organic reinforcing fiber is selected from the group consisting of polyalkylene terephthalates, polyalkylene naphthalates, polyamides, polyolefins, polyacrylonitrile and combinations thereof. 69. - The method of claim 68, wherein the fiber <; { ie organic reinforcement is polyethylene terephthalate. 70. The method of claim 65, wherein the inorganic rellenib is selected from the group consisting of talc, calcium carbonate, calcium hydroxide, barium sulfate, mica, calcium silicate, clay, kaolin, silica, alumina, volastonite, magnesium carbonate, magnesium hydroxide or, titanium oxide, zinc oxide, zinc sulfate, and combinations thereof. 71. - Claim 70, wherein the inorganic filler is talc or volastonite. 72. - The method of claim 6, wherein the dye fiber includes an inorganic pigment, an organic dye, or a combination thereof. 73. - The method of claim 72, wherein the dye fiber is selected from the group consisting of cellulosic fiber, acrylic fiber, nylon type fiber, pj_ type fiber, > liéster, and their combinations. 74. - The method of claim 73, wherein the polypropylene-based polymer further comprises an inorganic pigment, an organic dye or a combination thereof. 75. The method of claim 65, wherein the dye fiber has the form of a master batch comprising a carrier resin selected from the group consisting of polypropylene homopolymer, ethylene-propylene copolymer, ethylene-propylene terpolymer -butene-1, propylene-butene-1 copolymer, low polyethylene SUMMARY The present invention is generally directed to polypropylene compositions reinforced with cloth-like fiber, and the beneficial mechanical and aesthetic properties imparted by said compositions. Polypropylene compositions reinforced with fabric-like fiber include at least 25% by weight of polypropylene-based polymer, 5 to 60% by weight of organic reinforcing strip, 0 to 60% by weight of inorganic filler, and 0.1 to 2.5 I by weight of dye fiber. A method for forming fiber reinforced polypropylene compositions and molding articles thereof is also described and includes the steps of compounding the composition to form a resin by extrusion of double screw and injection molding the resin to form a similar article. to fabric. The molded articles of these fiber reinforced polypropylene compositions have a flexural modulus of at least 21090 kg / cm2, exhibit ductility during instrumented impact testing and exhibit a cloth-like appearance. The fabric-like fiber reinforced polypropylene compositions of the present invention are particularly suitable for forming molded articles including, but not limited to, household appliances, automotive parts and ship hulls.