IP Library Granted Patent US 12,163,011
Granted Patent B2
US 12,163,011 · App. 17/284,952 · Granted Dec 10, 2024

Upgraded recycled polyethylene polypropylene blend

Inventors: Susanne Kahlen (Linz, AT); Hermann Braun (Linz, AT); Yi Liu (Linz, AT); Markus Gahleitner (Linz, AT)
Assignee: BOREALIS AG
C08L23/04C08K3/34C08K5/01C08L23/10C08L2205/025C08L2207/20
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Quick Facts
Patent No.
US 12,163,011
App. No.
17/284,952
Granted
Dec 10, 2024
Kind
B2
Abstract

A polyethylene-polypropylene composition obtainable by blending a) 80 to 97 wt.-% of a blend (A) comprising A-1) polypropylene and A-2) polyethylene, wherein the weight ratio of polypropylene to polyethylene is from 3:7 to 7:3, and wherein blend (A) is a recycled material, which is recovered from a waste plastic material derived from post-consumer and/or industrial waste; and b) 3 to 20 wt.-% of a compatibilizer (B) being a C2C8 plastomer, having—a DSC melting point of below 75° C. (ISO11357); —an MFR 2 (ISO1133, 2.16 kg load at 190° C.) of equal or below 1.5 g/10 min; and—a density of equal or lower than 885 kg/m 3 (ISO1183), wherein the ratio of MFR 2 (blend (A) (ISO1133, 2.16 kg load at 230° C.)/MFR 2 (compatibilizer (B) (ISO1133, 2.16 kg load at 190° C.), is in the range 3.0 to 15; and c) 0 to 1.0 wt.-% of a stabilizer or mixture of stabilizers.

Claims (35)

1. A polyethylene-polypropylene composition obtainable by blending:

a) 80 to 97 wt. % of a blend (A) comprising:

A-1) polypropylene and

A-2) polyethylene,

wherein the weight ratio of polypropylene to polyethylene is from 3:7 to 7:3, and

wherein blend (A) is a recycled material, which is recovered from a waste plastic material derived from post-consumer and/or industrial waste; and

wherein blend (A) contains one or more of:

i) limonene as determined by using solid phase microextraction (HS-SPME-GC-MS) of greater than 0 ppm to less than 200 ppm,

ii) less than 6.0 wt. % polystyrene,

iii) less than 3 wt. % talc,

iv) less than 5.0 wt. % polyamide, and

v) less than 3 wt. % chalk;

b) 3 to 20 wt. % of a compatibilizer (B) being a C 2 C 8 plastomer, having:

a DSC melting point of 40 to 50° C. (ISO11357);

an MFR 2 (ISO1133, 2.16 kg load at 190° C.) of equal or below 1.5 g/10 min; and

a density of equal or lower than 885 kg/m 3 (ISO1183),

wherein the ratio of MFR 2 (blend (A) (ISO1133, 2.16 kg load at 230° C.)/MFR 2 (compatibilizer (B) (ISO1133, 2.16 kg load at 190° C.), is in the range 3.0 to 15; and

c) 0 to 1.0 wt. % of a stabilizer or mixture of stabilizers.

2. The polyethylene-polypropylene composition according to claim 1 , wherein the compatibilizer (B) has an MFR 2 (ISO1133, 2.16 kg load at 190° C.) of below 0.7 g/10 min.

3. The polyethylene-polypropylene composition according to claim 1 , wherein the compatibilizer (B) has a density of equal or lower than 875 kg/m 3 (ISO1183).

4. The polyethylene-polypropylene composition according to claim 1 , wherein the ratio of MFR 2 (blend (A) (ISO1133, 2.16 kg load at 230° C.)/MFR 2 (compatibilizer (B) (ISO1133, 2.16 kg load at 190° C.), is in the range 6.0 to 15.

5. The polyethylene-polypropylene composition according to claim 1 , whereby blend (A) has a content of limonene as determined by using solid phase microextraction (HS-SPME-GC-MS) of from 1 ppm to 100 ppm.

6. The polyethylene-polypropylene composition according to claim 1 , whereby blend (A) has a relative amount of units derived from ethylene of greater than 20 wt. % with respect to the total weight of blend (A).

7. A talc filled composition consisting of 0.1 to 20.0 wt. % talc and the polyethylene-polypropylene composition according to claim 1 .

8. An article comprising the polyethylene-polypropylene composition claim 1 .

9. A process for providing a polyethylene-polypropylene composition according to claim 1 , the process comprising the steps of:

a) providing blend (A) comprising polypropylene and polyethylene in a ratio of 3:7 to 7:3 in amount of at least 80 wt. %, based on the total weight of the polyethylene-polypropylene composition,

b) providing a compatibilizer (B) in an amount from 3 to 20 wt. %, based on the total weight of the polyethylene-polypropylene composition, whereby compatibilizer (B) is a C 2 C 8 plastomer, having:

a DSC melting point of 40 to 50° C. (ISO11357);

an MFR 2 (ISO1133, 2.16 kg load at 190° C.) of equal or below 1.5 g/10 min; and

a density of equal or lower than 885 kg/m 3 (ISO1183);

wherein the ratio of MFR 2 (blend (A) (ISO1133, 2.16 kg load at 230° C.)/MFR 2 (compatibilizer (B) (ISO1133, 2.16 kg load at 190° C.), is in the range 3.0 to 15;

c) melting and mixing the blend of blend (A) and the compatibilizer (B) in the presence of 0 to 1.0 wt. % of a stabilizer or a mixture of stabilizers, and

d) optionally pelletizing.

10. An article comprising a talc filled composition consisting of 0.1 to 20.0 wt. % talc and the polyethylene-polypropylene composition according to claim 1 .

Assignments (2)
CHANGE OF ADDRESS Recorded Feb 23, 2022
From: BOREALIS AG
To: BOREALIS AG
Reel/Frame 059219/0949 →
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Apr 13, 2021
From: KAHLEN, SUSANNE; BRAUN, HERMANN; LIU, YI; GAHLEITNER, MARKUS
To: BOREALIS AG
Reel/Frame 055904/0352 →