Polymer composition, method for preparing a molded article, molded article, and use of a polymer composition.

Abstract

POLYMER COMPOSITION, METHOD FOR PREPARING A MOLDED ARTICLE, MOLDED ARTICLE, AND USE OF A POLYMER COMPOSITION. A polymer composition may include from 10 to 90% by weight of at least one virgin polypropylene resin selected from a group consisting of propylene homopolymers, propylene random copolymers, propylene heterophasic copolymers and combinations thereof; and from 10 to 90% by weight of at least one recycled resin; wherein the polymer composition exhibits a melt flow index of 1 to 50 g / 10 min measured in accordance with ASTM D1238 (2.16 kg / 230°C), a flexural modulus at 1% secant measured in accordance with ASTM D790 of 900 to 1700 MPa, and an Izod impact strength at 23°C measured in accordance with ASTM D256 of 15 to 400 J / m.

Description

Polymer Composition, Method for Preparing a Molded Article, Molded Article, and Use of a Polymer Composition - Fundamentals

[001] Polyolefins such as polyethylene (PE) and polypropylene (PP) can be used to manufacture a wide range of articles, including films, molded products, foams, and the like. Polyolefins can exhibit characteristics such as high processability, low production cost, flexibility, low density, and recyclability. Although plastics such as polyethylene and polypropylene have many beneficial uses, the production and manufacture of plastics and plastic articles generally have a detrimental impact on the environment, including waste production and increased CO2 emissions during processing.

[002] One of the greatest challenges facing society today is reducing greenhouse gas emissions in order to minimize the impact on the climate and the environment. International agreements such as the 2015 Paris Agreement can establish limits on CO2 emissions and drive the transition to a low-carbon economy based on renewable energy, as well as the development of new economic and business models. In some cases, new production techniques and material solutions can be used to reduce the carbon footprint during plastic manufacturing, and a life cycle perspective can be applied to weigh the potential trade-offs between material functionality and environmental impact.

[003] Another major challenge for society is rethinking the use of plastic to reduce the environmental impact of waste. One option is to mechanically recycle consumed plastic to reintroduce it into the plastic value chain. Post-consumer recycled (PCR) resins are available on the market, but due to the high heterogeneity of sources and the chemical and chemical damage they pose, they are not readily available. Petition 870220073877, dated 08 / 17 / 2022, page 12 / 41 / 23 due to the mechanical stresses that plastic undergoes throughout its chain (from production to disposal), the properties of these resins are generally poor, making it a challenge to reuse them in many applications that require high property standards. SUMMARY

[004] This summary is provided to present a selection of concepts which are further described below in the detailed description. This summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used as an aid in limiting the scope of the claimed subject matter.

[005] In one aspect, the embodiments described herein refer to a polymer composition that includes from 10 to 90% by weight of at least one virgin polypropylene resin selected from a group consisting of propylene homopolymers, propylene random copolymers, propylene heterophasic copolymers and combinations thereof; and from 10 to 90% by weight of at least one recycled resin; wherein the polymer composition has a melt flow index of 1 to 50 g / 10 min measured in accordance with ASTM D1238 (2.16 kg / 230°C), a flexural modulus at 1% secant measured in accordance with ASTM D790 of 900 to 1700 MPa and an Izod impact strength at 23°C measured in accordance with ASTM D256 of 15 to 400 J / m.

[006] In another aspect, the embodiments described in this document refer to a method for preparing a molded article that includes dry mixing of PCR and virgin resin selected from polypropylene homopolymers, random polypropylene copolymers, heterophasic polypropylene copolymers, or combinations thereof to form a polymer composition; and molding the article from the polymer composition, wherein the polymer composition includes from 10 to 90% by weight of at least one virgin polypropylene resin selected from a Petition 870220073877, dated 08 / 17 / 2022, p. 13 / 41 / 23 group consisting of propylene homopolymers, propylene random copolymers, propylene heterophasic copolymers and combinations thereof; and 10 to 90% by weight of at least one recycled resin; wherein the polymer composition has a melt flow index of 1 to 50 g / 10 min measured in accordance with ASTM D1238 (2.16 kg / 230°C), a flexural modulus at 1% secant measured in accordance with ASTM D790 of 900 to 1700 MPa and an Izod impact strength at 23°C measured in accordance with ASTM D256 of 15 to 400 J / m.

[007] In another aspect, the embodiments described in this document refer to a method for preparing a molded article that includes melt mixing PCR and virgin resin selected from polypropylene homopolymers, polypropylene random copolymers, polypropylene heterophasic copolymers, or combinations thereof to form a polymer composition; and molding the article from the polymer composition, wherein the polymer composition includes 10 to 90% by weight of at least one virgin polypropylene resin selected from a group consisting of propylene homopolymers, propylene random copolymers, propylene heterophasic copolymers, and combinations thereof; and 10 to 90% by weight of at least one recycled resin;wherein the polymer composition has a melt flow index of 1 to 50 g / 10 min measured in accordance with ASTM D1238 (2.16 kg / 230°C), a flexural modulus at 1% secant measured in accordance with ASTM D790 of 900 to 1700 MPa, and an Izod impact strength at 23°C measured in accordance with ASTM D256 of 15 to 400 J / m.

[008] In yet another aspect, the embodiments described herein refer to a molded article comprising a polymeric composition including from 10 to 90% by weight of at least one virgin polypropylene resin selected from a group consisting of propylene homopolymers, propylene random copolymers, heterophasic copolymers of Petition 870220073877, dated 08 / 17 / 2022, page 14 / 41 / 23 propylene and its combinations; and from 10 to 90% by weight of at least one recycled resin; wherein the polymer composition has a melt flow index of 1 to 50 g / 10 min measured in accordance with ASTM D1238 (2.16 kg / 230°C), a flexural modulus at 1% secant measured in accordance with ASTM D790 of 900 to 1700 MPa and an Izod impact strength at 23°C measured in accordance with ASTM D256 of 15 to 400 J / m, wherein the molded article is selected from pallets, boxes, appliance parts, appliance housings, automotive parts, batteries, wheel well protectors, covers and fasteners.

[009] Other aspects and advantages of the claimed object will be evident from the following description and the appended claims. DETAILED DESCRIPTION

[0010] In one aspect, the embodiments described in this document refer to polymeric compositions and articles formed therefrom containing blended polymeric compositions of polypropylene and a recycled resin, such as post-consumer resin (PCR). As mentioned above, recycled resins such as post-consumer resins generally exhibit high heterogeneity of sources, and the properties of PCR are generally poor due to the chemical and mechanical damage that the plastic suffers during its production through disposal. However, the present description is directed to blended compositions of a recycled resin with a virgin polypropylene resin that achieve the desired properties. Recycled resin

[0011] In one or more embodiments, recycled resin may be selected from post-consumer resin (PCR), post-industrial resin (PIR) and / or remilled resin. PCR refers to resin that is recycled after its use by the consumer, while PIR refers to resin that is recycled from industrial materials and / or processes (e.g., cuts of materials used in the manufacture of other articles). When materials are recovered directly from Petition 870220073877, dated 08 / 17 / 2022, page 15 / 41 / 23 same manufacturing process, the materials can be called re-milled. In one or more embodiments, the PCR present in one or more blended polymer compositions may be a polyolefin. Generally, the PCR may include resins that were used in rigid applications (such as PCR of pre-blown articles, typically 3D shaped articles), as well as in flexible applications (such as films). In one or more particular embodiments, the PCR used in one or more blended polymer compositions may include PCR originally used in rigid applications. For example, PCR can be a polyolefin selected from polyethylene (such as HDPE, LDPE, LLDPE, MDPE, ULDPE, and UHDPE), polypropylene (such as homopolymers, random copolymers, and heterophasic copolymers), polybutylene, and polystyrene.In particular embodiments, the PCR may include at least 80% by weight of such polyolefins, for example, at least 80% by weight of the PCR formed from polypropylene. The PCR used may be any color, including but not limited to black, white, or gray, depending on the color used in the final article.

[0012] In one or more modalities, PCR may have a flow index in accordance with ASTM D1238 at 230°C / 2.16 kg with a lower limit selected from any of 5 g / 10 min, 7 g / 10 min and 10 g / 10 min to an upper limit selected from any of 15 g / 10 min, 20 g / 10 min, 25 g / 10 min and 30 g / 10 min, where any lower limit may be combined with any upper limit.

[0013] In one or more embodiments, the PCR may have a 1% secant bending modulus, measured in accordance with ASTM D790, greater than 900 MPa or in a range with a lower limit of 900, 950, or 1000 MPa and an upper limit of any one of 1050, 1100, or 1150 MPa, where any lower limit may be used in combination with any upper limit.

[0014] In one or more modalities, PCR may have resistance Petition 870220073877, dated 08 / 17 / 2022, p. 16 / 41 / 23 to Izod impact at 23°C, measured according to ASTM D256 with a lower limit of 25 J / m, 30 J / m or 35 J / m and an upper limit of any one of 45, 50 or 55 J / m. Virgin resin

[0015] The blended composition may include at least one virgin resin in combination with the PCR. The at least one virgin resin may be a polypropylene resin selected from propylene homopolymers, propylene random copolymers, propylene heterophasic copolymers, and combinations thereof.

[0016] Propylene homopolymers include, for example, less than 1% by weight of a comonomer selected from ethylene, alpha-olefins with 4 to 8 carbon atoms, or combinations thereof. Random copolymers of propylene include, for example, 1 to 6% by weight of an ethylene comonomer, alpha-olefins with 4 to 8 carbon atoms, or combinations thereof.

[0017] Heterophasic propylene copolymers (HECOs) include a continuous phase and a dispersed phase, where the continuous phase can be a propylene homopolymer or a propylene random copolymer. The dispersed phase can be an elastomer present in an amount ranging from a lower limit of 10, 15 or 20% by weight to an upper limit of 25, 30, 35 or 40% by weight, where any lower limit can be used in combination with any upper limit.

[0018] The elastomeric phase of the heterophasic propylene copolymer may be, for example, an elastomeric copolymer. The elastomeric copolymer may be a propylene copolymer comprising propylene and one or more comonomers. In one or more embodiments, the comonomers of the elastomeric copolymer may be one or more selected from a group consisting of ethylene, butene, and higher α-olefins. In particular embodiments, the comonomers may be selected from the Petition 870220073877, dated 08 / 17 / 2022, page 17 / 41 / 23 group consisting of ethylene and butene. The elastomeric copolymer may comprise one or more comonomers in an amount ranging from 20 to 70% by weight, relative to the weight of the elastomeric copolymer. In one or more embodiments, the elastomeric copolymer may comprise one or more comonomers in an amount ranging from a lower limit of any one of 15, 20, 25 or 30% by weight to an upper limit of 40, 50, 60 or 70% by weight, where any lower limit may be used with any upper limit. In one or more embodiments, the elastomeric copolymer may have an intrinsic viscosity, measured in accordance with ASTM D445 in decalin at 135°C, with a lower limit of 0.5, 1.0 or 1.5 dl / g and an upper limit of any one of 5, 6 or 7 dl / g, where any lower limit may be used with any upper limit.

[0019] The heterophasic propylene copolymer according to the present description may have a cold-soluble xylene content, measured in accordance with ASTM D5492, ranging from about 10 to 40% by weight. For example, the heterophasic propylene copolymer may have a cold-soluble xylene content with a lower limit of 10, 15, 18, 20, or 22% by weight and an upper limit of any one of 25, 30, 35, or 40% by weight, where any lower limit may be used in combination with any upper limit.

[0020] The heterophasic propylene copolymer according to the present description may have a comonomer content ranging from 3 to 30% by weight. For example, the heterophasic propylene copolymer may have a comonomer content with a lower limit of 3, 5 or 8% by weight and an upper limit ranging from any of 20, 25 or 30% by weight, where any lower limit may be used in combination with any upper limit.

[0021] Although one or more embodiments may use a virgin petrochemical polypropylene resin in the blended polymer compositions, in one or more particular embodiments, the virgin resin may be bio-based. In particular embodiments using a blend of bio-based resin Petition 870220073877, dated 08 / 17 / 2022, page 18 / 41 / 23 biological and recycled resin, the blended composition can have a particularly low carbon emission (or even carbon absorption) through the selection of the quantities of the two components in the blended composition.

[0022] Bio-based polypropylenes according to the present description may include polyolefins containing a weight percentage of biologically derived monomers. The propylene monomers may be derived from similar biological processes as discussed above in relation to bio-based polyethylene and discussed, for example, in US Patent Publ. 2013 / 0095542. In one or more embodiments, the biologically derived n-propanol may be dehydrated to produce propylene, which is then polymerized to produce various types of polypropylene. The bio-based polypropylene according to the present description may include a homopolymer, random copolymer, heterophasic copolymer or terpolymer and the like.

[0023] Bio-based polypropylenes according to the present description may include a polypropylene with a bio-based carbon content as determined by ASTM D6866-18 Method B in a percentage in a range with a lower limit selected from 5%, 8%, 10% and 20%, to an upper limit selected from 50%, 90% and 100%, where any lower limit may be combined with any upper limit.

[0024] In one or more modalities, bio-based products obtained from natural materials may be certified for their renewable carbon content, in accordance with the methodology described in the ASTM D 6866-06 technical standard, “Standard Test Methods for Determining the Biobased Content of Natural Range Materials Using Radiocarbon and Isotope Ratio Mass Spectrometry Analysis.”

[0025] In one or more embodiments, virgin polypropylene may have a melt flow index in accordance with ASTM D1238 at 230°C / 2.16 kg with a Petition 870220073877, dated 17 / 08 / 2022, p. 19 / 41 / 23 lower limit selected from any of 1 g / 10 min, 2 g / 10 min, 5 g / 10 min and 10 g / 10 min to an upper limit selected from any of 50 g / 10 min, 100 g / 10 min, 125 g / 10 min and 150 g / 10 min, where any lower limit may be combined with any upper limit. In particular,

[0026] In one or more embodiments, virgin polypropylene may have a density in accordance with ASTM D792 in a range with a lower limit selected from any of 0.800 g / cm3, 0.905 g / cm3, 0.910 g / cm3, 0.945 g / cm3 and 0.950 g / cm3 and an upper limit selected from any of 0.945 g / cm3, 0.955 g / cm3, 0.963 g / cm3 and 0.970 g / cm3, where any lower limit may be combined with any upper limit.

[0027] In one or more embodiments, virgin polypropylene may have a flexural modulus at 1% secant, measured in accordance with ASTM D790, in a range with a lower limit of 650, 750, 850 or 1000 MPa and an upper limit of any one of 1200, 1500 or 1700 MPa, where any lower limit may be used in combination with any upper limit.

[0028] In one or more embodiments, virgin polypropylene may have an Izod impact resistance at 23°C, measured in accordance with ASTM D256, of at least 10 J / m, 20 J / m or 30 J / m, inclusive up to no rupture. Mixed Polymer Composition

[0029] As mentioned above, one or more of the blended polymer compositions includes a mixture of virgin resin and recycled resin (such as PCR), and may be referred to as the blended polymer composition.

[0030] In one or more embodiments, blended polymer compositions containing virgin resin and recycled resin (such as PCR) may contain a percentage by weight, based on the total composition (% by weight) of the blend, of virgin polypropylene resin (which may optionally be bio-based) ranging from a lower limit selected from 10% by weight, 20% by weight, 25% by weight, 30% by weight, 40% by weight, 45% by weight Petition 870220073877, dated 17 / 08 / 2022, page 20 / 41 / 23 and 50% by weight to an upper limit selected from one of 50% by weight, 55% by weight, 60% by weight, 70% by weight, 75% by weight, 80% by weight and 90% by weight, where any lower limit may be used with any upper limit. Furthermore, it is foreseen that a polymer composition may optionally contain at least some amount of bio-based polypropylene (such as virgin resin) depending on the application and the desired carbon emission profile, discussed below.

[0031] In one or more embodiments, the blended polymer compositions may contain a percentage by weight, based on the total composition (% by weight) of the blend, of recycled resin content (such as PCR) ranging from a lower limit selected from 10% by weight, 20% by weight, 25% by weight, 30% by weight, 40% by weight, 45% by weight and 50% by weight to an upper limit selected from 50% by weight, 55% by weight, 60% by weight, 70% by weight, 75% by weight, 80% by weight and 90% by weight, where any lower limit may be used with any upper limit. Generally, the present compositions seek to increase the amount of recycled resin content while also achieving the desired compositional properties.Thus, it is understood that the amount of virgin polymer can always be increased; however, the present compositions can maximize the recycled resin content and minimize the virgin resin content, while achieving the desired final properties for the blended compositions. Furthermore, it is anticipated that a polymer composition may contain more or less PCR depending on the application and the desired carbon emission profile.

[0032] In one or more embodiments, methods for manufacturing blended polymer compositions may exhibit carbon emissions close to zero mass equivalents of CO2 per mass of polymer (i.e., kg of CO2 / kg of polymer). In some embodiments, the mass equivalents of CO2 per mass of a polymer composition may be Petition 870220073877, dated 17 / 08 / 2022, page 21 / 41 / 23 negative, indicating a carbon absorption (also referred to as carbon sequestration) of CO2 from the atmosphere. The blended polymer compositions according to the present description may include a mixture of a virgin (which may include an amount of bio-based resin and a petrochemical resin) and a recycled polymer composition (such as PCR), where the amount of each component is selected based on the carbon footprint calculated as determined by a “Factor of Emission” calculated as shown in Eq. 1: P1 biological base ' Emission factor P1 biological base + P2 recycled · Emission factor P2 recycled + P3 Petro · Emission factor P3 Petro = Emission factor mixture; where P1 bio-based is the weight percentage of virgin bio-based polypropylene, P2 recycled is the weight percentage of PCR, P3 Petro is the weight percentage of virgin petrochemical-based polypropylene; Emission Factor P1 bio-based is the emission calculated for virgin bio-based polypropylene in kg of CO2 / kg of PP, Emission Factor P2 recycled is the emission calculated for PCR in kg of CO2 / kg of PP, Emission Factor P3 Petro is the emission calculated for virgin petrochemical-based polypropylene, and Emission Factor mixture is the emission calculated for the polymer composition in kg of CO2 / kg of polymer composition. In one or more embodiments, the weight percentage of each component is selected so that the polymer composition has an Emission Factor Mixture less than or equal to 1.0 kg of CO2 / kg of polymer composition, as determined according to the formula mentioned above.In one or more embodiments, the blended composition may have a Blending Emission Factor in the range of -1 to 1 g of CO2 / kg of polymer composition. Although a range of Emission Factors is presented, it is anticipated that the Emission Factor may be approximately 0 or less negative than -1 in some embodiments, depending on the available starting materials and the application requirements of the final polymer composition. For example, in one or more embodiments, the Emission Factor... Petition 870220073877, dated 08 / 17 / 2022, page 22 / 41 / 23 Emission can have a lower limit of -1.0, -0.8, -0.6, -0.4, -0.2 or -0.1, and an upper limit of any one of 0.1, 0.2, 0.4, 0.6, 0.8 or 1.0, where any lower limit can be used in combination with any upper limit.

[0033] As described in this document, the Emission Factor of polymer compositions can be calculated according to the international standard ISO 14044:2006 - “ENVIRONMENTAL MANAGEMENT - LIFE CYCLE ASSESSMENT - REQUIREMENTS AND GUIDELINES”. The boundary conditions consider the cradle-to-gate approach. The figures are based on the peer-reviewed LCA-compliant ISO 14044 study and the environmental and life cycle model is based on SimaPro® software. Ecoinvent is used as the background database and IPCC 2013 GWP100 is used as the LCIA method.

[0034] When mixing PCR and virgin resin, in one or more embodiments, the blended polymer composition may have a melt flow index measured in accordance with ASTM D1238 at 230°C / 2.16 kg ranging from 1 to 50 g / 10 min. In particular, the melt flow index may have a lower limit ranging from 1, 2, 3, 5, 6, 8 or 10 g / 10 min to an upper limit of any one of 25, 30, 35, 40, 45, or 50 g / 10 min, where any lower limit may be used in combination with any upper limit.

[0035] In one or more embodiments, the blended polymer composition may include at least one additive selected from antioxidants, optical brighteners, processing aids, coloring agents, internal plasticizers, external plasticizers, nucleating agents, blowing agents, surface modifiers, neutralizing agents, and antistatic agents. For example, in one or more particular embodiments, the blended polymer composition may include at least 100 ppm of at least one antioxidant selected from phenolic, amino, phosphite, thioester, sulfur-based, and combinations thereof. In a particular embodiment, the antioxidants may be selected from Petition 870220073877, dated 08 / 17 / 2022, page. 23 / 41 / 23 tetracis(methylene(3,5-di-tert-butyl-4-hydroxyhydrocinnamate))methane, 1,3,5-trimethyl-2,4,6-tris(3,5-di-tert-butyl-4-hydroxybenzyl)benzene, Tris(2,4-di-tert-butylphenyl)phosphite, Bis(2,4-di-tert-butylphenyl)pentaerythritoldiphosphite, Ditridecylthiodipropionate, Bis-oxidized (hydrogenated tallow alkyl)amines, pentaerythritol-tetracis(3-(3',5'-di-tert-butyl-4-hydroxyphenyl)propionate; 1,3,5-trimethyl-2,4,6-tris-(3,5-di-tert-butyl-4-hydroxyphenyl)benzene, 1,3,5-Tris(3',5'-di-tert-butyl-4'-hydroxybenzyl)-isocyanurate), Di-stearyl-thio-di-propionate, Dilauryl-thio-di-propionate; Di-octadecyl-disulfide, pentaerythrityl-tetracis(3-(3',5'-di-tert-butyl-4-hydroxyphenyl)-propionate), Octadecyl-3-(3',5'-di-tert-butyl-4-hydroxyphenyl)-propionate), Bis(2,4-di-tert-butylphenyl)-pentaerythrityl-di-phosphite, Tetracis[methylene-3-(3',5'-di-t-4-hydroxyphenyl)propionate]methane, noctadecinyl-3-(4'-hydroxynyl)propionate and combinations thereof.Furthermore, in one or more embodiments, the blended polymer contains at least 100 ppm of either a primary antioxidant (e.g., hindered phenols or secondary aromatic amines) and at least 100 ppm of a secondary antioxidant (e.g., phosphites).

[0036] In addition, in one or more particular embodiments, the blended polymer composition may include at least 50 ppm of at least one neutralizing agent selected from stearates (e.g., calcium stearate) or magnesium aluminum hydroxycarbonate hydrate.

[0037] In addition, as mentioned above, PCR can be black, white, or gray, and the selection of these colors may depend on the color of the end-use article. The desired color can optionally be achieved by using a standard mixture of a pigmented composition (containing, for example, pigment in a carrier resin including, but not limited to, polyolefins (PE, PP, or combinations thereof)) which is added with the virgin resin and the recycled resin in the blended polymer composition. It is also foreseen that standard color mixtures may be added depending on the application, for example, in an amount greater than 1.0%. Petition 870220073877, dated 08 / 17 / 2022, page 24 / 41 / 23 by weight (solid or liquid).

[0038] The blended polymer composition may be formed by mixing (such as by dry mixing or melt mixing) PCR with a virgin polypropylene resin (optionally bio-based) and, in particular embodiments, the amounts selected for mixing may be selected based on consideration of CO2 emission reduction, as described above, to have an emission factor less than or equal to 1.0 kg CO2 / kg of blended polymer composition. It is also provided that the polymer composition may be formulated as a standard blend formulation that may be diluted in a subsequent melt mixing or dry mixing process to form the final polymer composition with improved properties. Solution

[0039] The polymer compositions according to the present description can be prepared from the constituent components using various techniques. In one or more embodiments, a virgin resin and PCR can be solubilized in a suitable organic solvent, such as decalin, 1,2-dichlorobenzene, 1,1,1,3,3,3-hexafluoroisopropanol and the like. The solvent mixture can then be heated to a temperature, such as between 23°C and 130°C, under stirring to mix the polymers. Extrusion

[0040] In one or more embodiments, the polymer compositions according to the present description can be prepared using continuous or discontinuous extrusion. The methods may use single, twin or multi-screw extruders, which can be used at temperatures ranging from 100°C to 270°C in some embodiments and from 140°C to 230°C in others. In some embodiments, the raw materials are added to an extruder, simultaneously or sequentially, at the main feeder or Petition 870220073877, dated 08 / 17 / 2022, p. 25 / 41 / 23 secondary in the form of powder, granules, flakes or dispersion in liquids such as solutions, emulsions and suspensions of one or more components.

[0041] The methods for preparing polymer compositions according to the present description may include the general steps of combining one or more virgin resins and PCR in an extruder; melt extrusion of one or more virgin resins and PCR as a blended polymer composition; and forming globules, films, sheets, or molded articles from the blended polymer composition. In one or more embodiments, the methods for preparing polymer compositions may involve a single extrusion or multiple extrusions following the sequences of the blending preparation stages.

[0042] In one or more embodiments, the components of the polymer composition can be pre-dispersed before extrusion using intensive mixers, for example. Inside an extrusion machine, the components are heated by heat exchange and / or mechanical friction, the phases are melted, and dispersion occurs by polymer deformation. In some embodiments, one or more compatibilizing agents (such as a functionalized polyolefin) between polymers of different natures can be used to facilitate and / or refine the distribution of the polymer phases and to allow the formation of conventional blend morphology and / or semi-interpenetrating network at the interface between the phases.

[0043] In one or more embodiments, the extrusion techniques according to the present description may also involve the preparation of a polymer composition concentrate (a standard mixture) which is then combined with other components to produce a polymer composition of the present description.

[0044] Extrusion-prepared polymer compositions may be in the form of granules that are applicable to different molding processes, including selected extrusion molding processes, Petition 870220073877, dated 08 / 17 / 2022, page 26 / 41 / 23 coextrusion molding, extrusion coating, injection molding, injection blow molding, injection and stretch blow molding, thermoforming, fused film extrusion, blown film extrusion, foam forming, blow molding and extrusion, injection stretch blow molding, rotomolding, pultrusion, calendering, additive manufacturing, lamination and the like, to produce manufactured articles.

[0045] In one or more embodiments, the article is an injection-molded article, a thermoformed article, a film, a foam, a blow-molded article, an additive-manufactured article, a compressed article, a coextruded article, a laminated article, an injection blow-molded article, a rotomolded article, an extruded article, single-layer articles, multi-layer articles, or a pultruded article and the like. In embodiments of a multi-layer article, it is provided that at least one of the layers comprises the polymer composition of the present description. Applications

[0046] In one or more embodiments, polymer compositions can be used in the manufacture of articles including rigid packaging, tanks, water and gas pipes, lids, closures, injection-molded parts, small volume blow-molded articles, large volume blow-molded articles, foams, expanded articles, thermoformed articles, parts for household appliances (such as in washing machines including casing and agitator), injection-molded articles, household goods, technical parts, air ducts, automotive parts and reservoirs (such as battery housings and headlights and wheel guards), transport articles (such as pallets and boxes), cylinders, perforated reels, cisterns, water tanks, boxes, garbage cans, waste collectors, pipe shoulders, tubes, ropes, oriented structures, plastic furniture, battery boxes, crates, plates, sheets, tubes, pipes, containers, electronic articles, IBCs (intermediate bulk containers), water tanks, septic tanks and other types of Petition 870220073877, dated 08 / 17 / 2022, p. 27 / 41 / 23 tanks.

[0047] In one or more embodiments, the constitution of the mixed composition, the properties of the components and the mixture found can be selected based on the type of article being produced, such as depending on whether it is a molded article, appliance component or lid / closure.

[0048] Molded articles may, in one or more embodiments, use a mixture of virgin polypropylene (present in an amount ranging from 20 to 50% by weight) and PCR (present in an amount ranging from 50 to 80% by weight) to have a blended polymer composition with a melt flow index with a lower limit of 1, 2 or 5 g / 10 min to an upper limit of either 20, 35 or 50 g / 10 min measured in accordance with ASTM D1238 (2.16 kg / 230°C) where any lower limit may be used with any upper limit; A bending modulus at 1% secant measured in accordance with ASTM D790 with a lower limit of 900, 950, or 1000 MPa, up to an upper limit of any one of 1500, 1600, or 1700 MPa, where any lower limit may be used with any upper limit;and an Izod impact resistance at 23°C measured in accordance with ASTM D256 having a lower limit of 15, 20 or 25 J / m and an upper limit of any one of 150, 200, 300 or 400 J / m, where any limit may be used with any upper limit.

[0049] For example, one or more embodiments relate to molded items that may include automotive components such as batteries, wheel well protection, and may include a combination of PCR with a heterophasic polypropylene copolymer (HECO). The HECO may have a melt flow index measured according to ASTM D1238 (2.16 kg / 230°C) ranging from 2 g / 10 min to 5 g / 10 min, a 1% secant flexural modulus measured according to ASTM D790 greater than 850 MPa, an Izod impact strength at 23°C measured according to ASTM D256 greater than 400 J / m, Petition 870220073877, dated 08 / 17 / 2022, p. 28 / 41 / 23 and an ethylene content ranging from 10 to 15%. PCR may have a melt flow index measured according to ASTM D1238 (2.16 kg / 230°C) of 7 to 30 g / 10 min, a flexural modulus at 1% secant measured according to ASTM D790 greater than 900 MPa, and an Izod impact strength at 23°C measured according to ASTM D256 ranging from more than 25 J / m. HECO and PCR can be mixed in a weight ratio ranging from 20 / 80 to 50 / 50, allowing for the maximization of PCR content in the mixed composition while achieving a melt flow index measured according to ASTM D1238 (2.16 kg / 230°C) of 5 to 15 g / 10 min, a flexural modulus at 1% secant measured according to ASTM D790 greater than 900 to 1300 MPa, and an Izod impact strength at 23°C measured according to ASTM D256 greater than 90 J / m. However, it is also understood that a PCR content of less than 50% by weight can also be used in some embodiments.

[0050] One or more embodiments relate to molded items which may include transport items such as pallets and boxes, and which may include a combination of PCR with a heterophasic polypropylene copolymer (HECO). The HECO may have a melt flow index measured according to ASTM D1238 (2.16 kg / 230°C) ranging from 2 g / 10 min to 5 g / 10 min, a 1% secant flexural modulus measured according to ASTM D790 greater than 850 MPa, an Izod impact strength at 23°C measured according to ASTM D256 greater than 400 J / m, and an ethylene content ranging from 10 to 15%. PCR may have a melt flow index measured according to ASTM D1238 (2.16 kg / 230°C) greater than 10 g / 10 min, a flexural modulus at 1% secant measured according to ASTM D790 greater than 1050 MPa, and an Izod impact strength at 23°C measured according to ASTM D256 greater than 25 J / m.HECO and PCR can be mixed in a weight ratio ranging from 20 / 80 to 50 / 50, which allows for maximizing the PCR content in the mixture while achieving a melt flow index measured according to ASTM D1238 (2.16 kg / 230°C) of 5 to 15 g / 10. Petition 870220073877, dated 08 / 17 / 2022, p. 29 / 41 / 23 min, a flexural modulus at 1% secant measured according to ASTM D790 greater than 850 to 1300 MPa and an Izod impact strength at 23°C measured according to ASTM D256 greater than 110 J / m. However, it is also understood that a PCR content of less than 50% by weight may also be used in some applications.

[0051] Apparatus parts may, in one or more embodiments, use a mixture of virgin polypropylene (present in an amount ranging from 10 to 60% by weight) and PCR (present in an amount ranging from 40 to 90% by weight) to have a blended polymer composition with a melt flow index having a lower limit of 3, 5 or 8 g / 10 min to an upper limit of either 15, 18 or 30 g / 10 min measured in accordance with ASTM D1238 (2.16 kg / 230°C) where any lower limit may be used with any upper limit; A 1% secant bending modulus measured in accordance with ASTM D790 with a lower limit of 950 or 1000 MPa, up to an upper limit of any one of 1200, 1300, 1400, 1500 or 1600 MPa, where any lower limit may be used with any upper limit;and an Izod impact resistance at 23°C measured in accordance with ASTM D256 having a lower limit of 15, 20 or 25 J / m and an upper limit of any one of 100, 125 or 150 J / m, where any limit may be used with any upper limit.

[0052] For example, one or more embodiments relate to appliance parts, such as washing machine agitators, which may include a combination of PCR with a virgin polypropylene homopolymer. The virgin polypropylene homopolymer may have a melt flow index measured according to ASTM D1238 (2.16 kg / 230°C) ranging from 2 g / 10 min to 4.2 g / 10 min, a 1% secant flexural modulus measured according to ASTM D790 of at least 1850 MPa, an Izod impact strength at 23°C measured according to ASTM D256 of at least 20 J / m, and a xylene content of less than 2% by weight. The PCR may have a melt flow index Petition 870220073877, dated 08 / 17 / 2022, p. 30 / 41 / 23 measured according to ASTM D1238 (2.16 kg / 230°C) of at least 10 g / 10 min, a 1% secant bending modulus measured according to ASTM D790 greater than 1050 MPa, and an Izod impact strength at 23°C measured according to ASTM D256 greater than 25 J / m. Polypropylene and PCR can be mixed in a weight ratio ranging from 10 / 90 to 60 / 40, allowing for the maximization of PCR content in the mixed composition while achieving a melt flow index measured according to ASTM D1238 (2.16 kg / 230°C) of 7 g / 10 min to 12 g / 10 min, a flexural modulus at 1% secant measured according to ASTM D790 greater than 1400 MPa, and an Izod impact strength at 23°C measured according to ASTM D256 greater than 25 J / m. However, it is also understood that a PCR content of less than 40% by weight can also be used in some embodiments.

[0053] One or more other embodiments relate to appliance parts, such as a washing machine housing, which may include a combination of PCR with a heterophasic polypropylene copolymer (HECO). The HECO may have a melt flow index measured according to ASTM D1238 (2.16 kg / 230°C) ranging from 30 g / 10 min to 55 g / 10 min, a 1% secant flexural modulus measured according to ASTM D790 greater than 1000 to 1400 MPa, an Izod impact strength at 23°C measured according to ASTM D256 ranging from more than 70 J / m, and an ethylene content ranging from 6 to 10%. PCR can have a melt flow index measured according to ASTM D1238 (2.16 kg / 230°C) of 7 to 30 g / 10 min, a 1% secant flexural modulus measured according to ASTM D790 greater than 900 MPa, and an Izod impact strength at 23°C measured according to ASTM D256 ranging from more than 25 J / m.HECO and PCR can be mixed in a weight ratio ranging from 10 / 90 to 60 / 40, which allows for maximizing the PCR content in the mixture while achieving a melt flow index measured according to ASTM D1238 (2.16 kg / 230°C) of 15 to 30 g / 10 min, and a flexural modulus at 1% secant measured according to... Petition 870220073877, dated 08 / 17 / 2022, pp. 31 / 41 / 23 ASTM D790 greater than 1100 MPa, an Izod impact strength at 23°C measured according to ASTM D256 greater than 50 J / m. However, it is also understood that a PCR content of less than 40% by weight may also be used in some applications.

[0054] Caps and closures may, in one or more embodiments, use a mixture of virgin polypropylene (present in an amount ranging from 10 to 60% by weight) and PCR (present in an amount ranging from 40 to 90% by weight) to have a blended polymer composition with a melt flow index having a lower limit of 5, 8 or 10 g / 10 min to an upper limit of either 20, 25 or 30 g / 10 min measured in accordance with ASTM D1238 (2.16 kg / 230°C) where any lower limit may be used with any upper limit; A flexural modulus at 1% secant measured in accordance with ASTM D790 with a lower limit of 1000, 1050, or 1100 MPa, up to an upper limit of any one of 1300, 1400, or 1500 MPa, where any lower limit may be used with any upper limit;and an Izod impact resistance at 23°C measured in accordance with ASTM D256 having a lower limit of 30, 40 or 50 J / m and an upper limit of any one of 140, 160 or 180 J / m, where any limit may be used with any upper limit.

[0055] For example, one or more embodiments relate to caps and closures, such as screw caps or snap closures, which may include a combination of PCR with a heterophasic polypropylene copolymer (HECO). The HECO may have a melt flow index measured according to ASTM D1238 (2.16 kg / 230°C) ranging from 30 g / 10 min to 55 g / 10 min, a 1% secant flexural modulus measured according to ASTM D790 of less than 1400 MPa, an Izod impact strength at 23°C measured according to ASTM D256 ranging from 70 to 100 J / m, and an ethylene content ranging from 6 to 10%. PCR can have a melt flow index measured according to ASTM D1238 (2.16 kg / 230°C) of 7 to 30 g / 10 min, a flexural modulus Petition 870220073877, dated 08 / 17 / 2022, p. 32 / 41 / 23, with a 1% secant measured according to ASTM D790 greater than 900 MPa and an Izod impact strength at 23°C measured according to ASTM D256 ranging from more than 25 J / m. HECO and PCR can be mixed in a weight ratio ranging from 10 / 90 to 60 / 40, allowing for the maximization of PCR content in the mixed composition while achieving a melt flow index measured according to ASTM D1238 (2.16 kg / 230°C) of 15 to 30 g / 10 min, a flexural modulus at 1% secant measured according to ASTM D790 greater than 1100 MPa, and an Izod impact strength at 23°C measured according to ASTM D256 greater than 45 J / m. However, it is also understood that a PCR content of less than 40% by weight can also be used in some embodiments.

[0056] One or more other embodiments relate to caps and closures, such as for chemical containers, which may include a combination of PCR with a virgin polypropylene homopolymer. The virgin polypropylene homopolymer may have a melt flow index measured in accordance with ASTM D1238 (2.16 kg / 230°C) ranging from 2 g / 10 min to 4.2 g / 10 min, a 1% secant flexural modulus measured in accordance with ASTM D790 of at least 1850 MPa, and an Izod impact strength at 23°C measured in accordance with ASTM D256 of at least 20 J / m. PCR may have a melt flow index measured in accordance with ASTM D1238 (2.16 kg / 230°C) of at least 10 g / 10 min, a 1% secant flexural modulus measured in accordance with ASTM D790 greater than 1050 MPa, and an Izod impact strength at 23°C measured in accordance with ASTM D256 greater than 25 J / m.Virgin polypropylene and PCR can be mixed in a weight ratio ranging from 10 / 90 to 60 / 40, which allows for maximizing the PCR content in the blended composition while achieving a melt flow index measured according to ASTM D1238 (2.16 kg / 230°C) of 7.5 g / 10 min to 12 g / 10 min, a flexural modulus at 1% secant measured according to ASTM D790 greater than 1350 MPa, and an Izod impact strength of . Petition 870220073877, dated 08 / 17 / 2022, pp. 33 / 41 / 23 23°C measured according to ASTM D256 greater than 45 J / m². However, it is also understood that a CRP content of less than 40% by weight may also be used in some modalities.

[0057] Although only a few exemplary embodiments have been described in detail above, those skilled in the art will readily recognize that many modifications are possible in the exemplary embodiments without materially departing from this invention. Therefore, all such modifications should be included within the scope of this description, as defined in the following claims. In the claims, the half-plus-function clauses are intended to cover the structures described herein as performing the cited function and not merely structural equivalents, but also equivalent structures. Thus, although a nail and a screw may not be structural equivalents, since a nail uses a cylindrical surface to fasten pieces of wood, while a screw uses a helical surface, in the environment of fastening pieces of wood, a nail and a screw can be equivalent structures. It is the express intention of the applicant not to invoke 35 USCSection 112, paragraph 6, applies to any limitations of any of the claims contained herein, except those in which the claim expressly uses the words 'means to' along with an associated function.

Claims

1. Polymer composition, characterized in that it comprises: 10 to 90% by weight of at least one virgin polypropylene resin selected from a group consisting of propylene homopolymers, propylene random copolymers, propylene heterophasic copolymers and combinations thereof; at least one virgin polypropylene resin having a melt flow index measured according to ASTM D1238 at 230°C / 2.16 kg, of 1 to 150 g / 10 min; and an Izod impact strength at 23°C, measured according to ASTM D256, of at least 10 J / m; and 10 to 90% by weight of at least one post-consumer resin, PCR, the PCR having a melt flow index measured according to ASTM D1238 at 230°C / 2.16 kg, of 5 g / 10 min to 30 g / 10 min; a flexural modulus at 1% secant measured according to ASTM D790, greater than 900 MPa; and an Izod impact strength at 23°C measured according to ASTM D256, of 25 J / m 55 J / m;wherein the polymer composition has a melt flow index of 1 to 50 g / 10 min measured according to ASTM D1238 (2.16 kg / 230°C), a flexural modulus at 1% secant measured according to ASTM D790 of 900 to 1700 MPa, and an Izod impact strength at 23°C measured according to ASTM D256 of 15 to 400 J / m; wherein the virgin polypropylene is a bio-based polypropylene or a combination of a bio-based polypropylene and a petrochemical-based propylene; and wherein the polymer composition has a bio-based carbon content as determined by ASTM D686618 Method B of at least 5%.

2. Polymer composition according to claim 1, Petition 870240108785, dated 12 / 19 / 2024, page 10 / 22 2 / 6 characterized in that virgin polypropylene resin is present in an amount ranging from 10 to 50% by weight and recycled resin is present in an amount ranging from 40 to 90% by weight; and wherein the polymer composition has a melt flow index of 3 to 30 g / 10 min measured according to ASTM D1238 (2.16 kg / 230°C), a flexural modulus at 1% secant measured according to ASTM D790 of 950 to 1600 MPa and an Izod impact strength at 23°C measured according to ASTM D256 of 15 to 150 J / m.

3. Polymer composition according to claim 1, characterized in that virgin polypropylene resin is present in an amount ranging from 10 to 50% by weight and recycled resin is present in an amount ranging from 40 to 90% by weight; and wherein the polymer composition has a melt flow index of 5 to 30 g / 10 min measured according to ASTM D1238 (2.16 kg / 230°C), a flexural modulus at 1% secant measured according to ASTM D790 of 1000 to 1500 MPa and an Izod impact strength at 23°C measured according to ASTM D256 of 30 to 180 J / m.

4. Polymer composition according to any of the preceding claims, characterized in that the polymer composition has a density measured according to ASTM D 792 greater than 0.850 g / cm3.

5. Polymer composition according to any of the preceding claims, characterized in that the % by weight of each component is selected so that the polymer composition has a Mixture Emission Factor less than or equal to 1.0 kg of CO2 / kg of polymer composition, as determined according to the formula: P1bio-based · Emission factor p1bio-based + P2recycled · Emission factor p2recycled + P3petro · Emission factor p3petro = Mixture Emission Factor; where P1bio-based is the percentage by weight of polypropylene. Petition 870240108785, dated 12 / 19 / 2024, p.11 / 22 3 / 6 of virgin bio-based, P2recycled is the percentage by weight of recycled resin, P3Petro is the percentage by weight of virgin petrochemical-based polypropylene; Emission factor P1bio-based is the emission calculated for virgin bio-based polypropylene in kg of CO2 / kg of PP, Emission factor P2recycled is the emission calculated for recycled resin in kg of CO2 / kg of PP, Emission factor P3Petro is the emission calculated for virgin petrochemical-based polypropylene, and Emission factor mixture is the emission calculated for the polymer composition in kg of CO2 / kg of polymer composition.

6. Polymer composition according to claim 5, characterized in that the composition has a Mixture Emission Factor in the range of -1 to 1 g of CO2 / kg of polymer composition.

7. Polymer composition according to any of the preceding claims, characterized in that the virgin polypropylene has a flexural modulus at 1% secant, measured according to ASTM D790, ranging from 650 to 1700 MPa.

8. Polymer composition according to any of the preceding claims, characterized in that: - the propylene homopolymer comprises 0 to 1% by weight of at least one comonomer selected from ethylene, alpha-olefins comprising 4 to 8 carbon atoms and combinations thereof; and / or - the propylene random copolymer comprises 1 to 6% by weight of at least one comonomer selected from ethylene, alpha-olefins comprising 4 to 8 carbon atoms and combinations thereof; and / or - the propylene heterophasic copolymer comprises: a continuous phase selected from propylene homopolymers and propylene random copolymers comprising 0 to 6% by weight of a comonomer selected from ethylene, alpha-olefins with 4 to 8 carbon atoms and combinations thereof; and / or Petition 870240108785, dated 12 / 19 / 2024, p.12 / 22 4 / 6 8 carbon atoms and combinations thereof; and a rubber phase dispersed in an amount ranging from 10 to 40% by weight of the heterophasic propylene copolymer, wherein the dispersed rubber phase comprises 20 to 70% by weight of a comonomer selected from ethylene, alpha-olefins with 4 to 8 carbon atoms and combinations thereof, with an intrinsic viscosity of 0.5 to 7.0 dl / g measured according to ASTM D445 in decalin at 135°C; wherein the heterophasic propylene copolymer has 10 to 40% by weight of cold-soluble xylene measured according to ASTM D5492 and a comonomer content ranging from 3 to 30% by weight of a total comonomer content.

9. Polymer composition according to any of the preceding claims, characterized in that at least 80% by weight of the PCR comprises polyolefins selected from polyethylenes, polypropylenes, polybutylenes and polystyrene; wherein, optionally, at least 80% by weight of the PCR comprises polypropylene.

10. Polymer composition according to any of the preceding claims, characterized in that the polymer composition further comprises at least one additive selected from antioxidants, optical brighteners, processing aids, coloring agents, internal plasticizers, external plasticizers, nucleating agents, blowing agents, surface modifiers, neutralizing agents and antistatic agents.

11. Polymer composition according to any of the preceding claims, characterized in that it further comprises at least 100 ppm of at least one antioxidant selected from tetracis(methylene(3,5-di-tert-butyl-4-hydroxyhydrocinnamate))methane, 1,3,5-trimethyl-2,4,6-tris(3,5-di-tert-butyl-4-hydroxybenzyl)benzene, Tris(2,4-di-tert-butylphenyl)phosphite, Bis(2,4-di-t Petition 870240108785, dated 12 / 19 / 2024, page.13 / 22 5 / 6 butylphenyl) Pentaerythritol Diphosphite, Ditridecyl thiodipropionate, Bis oxidized (hydrogenated tallow alkyl) amines, pentaerythritol-tetracis(3-(3',5'-di-tert-butyl-4-hydroxyphenyl)-propionate; 1,3,5-trimethyl-2,4,6-tris-(3,5-di-tert-butyl-4-hydroxyphenyl)benzene, 1,3,5-Tris(3',5'-di-tert-butyl-4'-hydroxybenzyl)isocyanurate), Di-stearyl-thio-di-propionate, Di-lauryl-thio-di-propionate; Dioctadecyl disulfide, pentaerythrityl tetracis(3-(3',5'-di-tert-butyl-4-hydroxyphenyl)propionate), Octadecyl-3-(3',5'-di-tert-butyl-4-hydroxyphenyl)propionate), Bis(2,4-di-tert-butylphenyl)-pentaerythrityl di-phosphite, Tetracis[methylene-3-(3',5'-di-t-4-hydroxyphenyl)propionate]methane, noctadecinyl-3-(4'-hydroxynyl)propionate and combinations thereof; and / or further comprises at least 50 ppm of at least one neutralizing agent selected from aluminum and magnesium hydroxylcarbonate stearates or hydrates.

12. Method for preparing a molded article, the method characterized in that it comprises: dry or melt mixing PCR and virgin resin selected from polypropylene homopolymers, random polypropylene copolymers, heterophasic polypropylene copolymers or combinations thereof to form the polymer composition as defined in any of the preceding claims; and molding the article from the polymer composition.

13. Method according to claim 12, characterized in that the molding is selected from blow molding and extrusion, injection blow molding, injection molding, thermoforming and foam blow molding.

14. Molded article, characterized in that it comprises the polymer composition as defined in any one of claims 1 to 11, wherein the molded article is selected from pallets, boxes, appliance parts, appliance housings, automotive parts, batteries, wheel well protectors, covers and fasteners.

15. Use of a polymer composition comprising at least one virgin polypropylene and one PCR resin, characterized in that it is for forming a molded article as defined in claim 14.