Polyolefin composition comprising a polypropylene homopolymer and a recycled plastic material

Abstract

The present invention relates to a polyolefin composition comprising: a) at least one polypropylene homopolymer; b) a blend (A) of a recycled plastic material comprising polypropylene and polyethylene in a ratio of 3:7 to 10:1, said blend (A) being recycled from waste plastic material derived from post-consumer waste and / or post-industrial waste; c) glass fibers; and d) at least one coupling agent; wherein the polyolefin composition is characterized by a melt flow rate MFR2 (230°C, 2.16 kg, measured according to ISO 1133) of at least 2 g / 10 min; a tensile modulus (ISO 527-2) of at least 4 GPa and an impact strength (ISO 179-1, Charpy 1 eA + 23°C) of at least 6 kJ / m 2 2.

Description

[0001] This invention relates to polyolefin compositions comprising at least one polypropylene homopolymer and recycled plastic material, articles comprising said polyolefin compositions, and methods for preparing such polyolefin compositions.

[0002] describe

[0003] Polyolefins, particularly polyethylene and polypropylene, are increasingly being consumed in large quantities across a wide range of applications, including packaging for food and other items, fibers, automotive components, and a wide variety of manufactured articles. Polyethylene-based materials present a particular challenge due to their extensive use in packaging. Given the enormous volume of waste collected compared to the amount recycled back into the stream, intelligent reuse of plastic waste streams and mechanical recycling of plastic waste still hold significant potential.

[0004] Typically, large quantities of recycled polypropylene on the market are mixtures of polypropylene (PP) and polyethylene (PE), especially in post-consumer waste streams. Furthermore, commercially recycled materials from post-consumer waste sources are routinely cross-contaminated with non-polyolefin materials (such as polyethylene terephthalate, polyamide, and polystyrene) or non-polymer materials (such as wood, paper, glass, or aluminum). This cross-contamination severely limits the end-use of the recycled stream, leaving little room for beneficial final applications. Polyolefin recycled materials, especially those from post-consumer waste streams, are mixtures of PE and PP. The higher the quality of the recycled material, the less available it is, and the more expensive it becomes.

[0005] Consumers seeking recycled materials require stiffness-impact strength similar to virgin materials. This is also effective for reinforced glass fiber compounds used in structural products. The quality issues of recycled materials compared to virgin materials can be overcome to some extent by reinforcing them with different domains (PP and PE) where the reinforcing particles are physically combined.

[0006] Compositions containing virgin polymers (i.e., polymers used for the first time) and recycled blended plastics were investigated.

[0007] WO 2014167493 A1 describes a method for preparing a polyolefin blend, the method comprising step (a) of mixing a base polymer blend MB and a polymer blend MPR together, wherein the MPR is obtained from the recycling of post-consumer plastic materials.

[0008] Recycled plastic blends reinforced with glass fiber (GF) were also investigated. For example, recycled PP or PP / PE blends were reinforced with GF or blended GF with other fillers.

[0009] EP 2845876 B1 describes a composition comprising two or more resins and glass fibers, the composition comprising: a resin mixture comprising waste polyethylene (PE) and waste polypropylene (PP); long glass fibers having a length of 10 mm or greater; and a rubber-based resin, wherein based on 100 parts by weight of the resin mixture, the composition comprises 3 to 30 parts by weight of the long glass fibers, 10 to 50 parts by weight of the rubber-based resin, and 10 to 35 parts by weight of LDPE.

[0010] EP 3406662 A1 describes structurally reinforced plastic composite products produced from recycled waste glass fibers and recycled polymer compounds, and methods for manufacturing the same. The reinforced composite article comprises: recycled glass fibers collected from a waste stream and used as filler, the recycled glass fibers comprising 30% to 70% of the total weight of the reinforced composite article; a colorant comprising 1% to 2% of the total weight of the reinforced composite article; and a recycled resin collected from a waste stream and substantially wetted by a black colorant and a chemical binder. The recycled resin includes at least one of high-density polyethylene (HDPE), polypropylene (PP), or engineering-grade resin.

[0011] Bajracharya et al. (Experimental and theoretical studies on the properties of injection molded glass fiber reinforced mixed plastics composites. *Composites Part A: Applied Science and Manufacturing*, 2016, 84: 393-405) and Bajracharya et al. (Durability characteristics and property prediction of glass fiber reinforced mixed plastics composites. *Composites Part B: Engineering*, 2017, 116: 16-29) used sheet-like PE / PP recycled materials collected from post-consumer and post-industrial plastic waste by Repeat Plastics (Replas) Pty in Australia. The recycled materials had a tensile modulus of 906 MPa. They were reinforced with 10%, 20%, and 30% GF (4.0 mm in length and 13.7 μm in diameter). A maximum tensile modulus of 3068 MPa was achieved with 30% GF.

[0012] Therefore, there are instances of reinforced recyclers that simultaneously possess good tensile modulus and impact strength. However, it would be advantageous to provide polyolefin compositions with properties similar to virgin polymers but also containing post-consumer recyclables (PCRs) to make the final solution more cost-effective in terms of CO2 footprint.

[0013] Therefore, the object of the present invention is to provide a polyolefin composition comprising polyolefin material recycled from waste plastic materials, having an improved stiffness-impact strength balance.

[0014] This objective is achieved by providing a polyolefin composition comprising the following:

[0015] a) 30% to 60% by weight (based on the total weight of the polymer composition) of at least one polypropylene homopolymer.

[0016] b) A blend (A) of recycled plastic material comprising 15% to 40% by weight (based on the total weight of the polymer composition) in a ratio of 3:7 to 10:1 of polypropylene and polyethylene, said blend (A) being recycled from waste plastic material derived from post-consumer and / or post-industrial waste, said blend (A) having a melt flow rate MFR2 (230°C, 2.16 kg, measured according to ISO 1133) in the range of 8 g / 10 min to 14 g / 10 min.

[0017] c) 17% to 50% by weight (based on the total weight of the polymer composition) of glass fiber;

[0018] d) At least one coupling agent, in amounts ranging from 0.5% to 2.5% by weight (based on the total weight of the polymer composition), and optionally additional additives, wherein the sum of all components is always 100% by weight.

[0019] The polyolefin composition has

[0020] - A melt flow rate (MFR2) of at least 2 g / 10 min (230 °C, 2.16 kg, measured according to ISO 1133);

[0021] - A tensile modulus of at least 4 GPa (measured according to ISO 527-2, 23°C), and

[0022] -At least 5kJ / m 2 Impact strength (Charges 1eA + 23℃).

[0023] The recycled materials comprising the composition of this invention are characterized by a combination of high tensile modulus and high impact strength. The properties of combinations of different types of polymers with glass fiber reinforced recycled materials are not easily predicted. Tensile modulus is particularly difficult to predict due to the interactions between different components. Furthermore, the recycled polyolefins are often contaminated with polar polymers (e.g., PA, PET) or other non-polar polymers (non-PO) (e.g., PS or fillers), making precise calculation of the final mechanical properties even more challenging.

[0024] As discussed in further detail below, the melt flow rates of the polyolefin compositions of the present invention can cover a wide range and can be adjusted according to consumer needs. Melt flow rate is an important indicator of flow in the mold. Variations in melt flow rate affect the conversion interface and end-use performance. By providing polyolefin compositions with different melt flow rates, consumer needs can be met.

[0025] It should be understood that the polyolefin compositions of the present invention are free of rubber and substantially free of peroxides, and preferably, the peroxide content is less than 0.5% by weight based on the total weight of the polymer composition.

[0026] For the purposes of this specification and the appended claims, the term "recycled" is used to indicate the recovery of materials from post-consumer waste and / or industrial waste. That is, post-consumer waste refers to objects that have completed at least one first use cycle (or life cycle), i.e., have experienced their first purpose and have passed through the hands of a consumer; while industrial waste refers to manufacturing waste that typically does not reach consumers. In the spirit of this invention, based on the total weight of the recycled polymer, the "recycled polymer" may also contain up to 17% by weight, preferably up to 3% by weight, more preferably up to 1% by weight, and even more preferably up to 0.1% by weight of other components derived from the first use. The type and amount of these components affect the physical properties of the recycled polymer. The physical properties given below relate to the main components of the recycled polymer.

[0027] As further described below, other typical components derived from the first use include thermoplastic polymers (such as polystyrene and PA6), talc, chalk, ink, wood, paper, limonene, and fatty acids. The content of polystyrene (PS) and polyamide 6 (PA6) in the recycled polymer can be determined by Fourier transform infrared spectroscopy (FTIR), and the content of talc, chalk, wood, and paper can be measured by thermogravimetric analysis (TGA).

[0028] The term "virgin" refers to newly generated materials and / or objects that are not recycled before their first use. Unless the source of the polymer is explicitly mentioned, the polymer is referred to as a "virgin" polymer.

[0029] As further described below, more than one polypropylene homopolymer may be used in the polyolefin composition. At least one multiphase polypropylene copolymer may also be added to the polyolefin composition of the present invention.

[0030] According to the present invention, the total amount of all virgin polypropylene polymers (homopolymers and multiphase polymers) used in the polyolefin composition of the present invention is added together in the range of 30% to 60% by weight, preferably 30% to 50% by weight, more preferably 35% to 45% by weight, and even more preferably 37% to 40% by weight (based on the total weight of the polymer composition).

[0031] According to the present invention, the amount of a blend (A) containing recycled plastic material of polypropylene and polyethylene in a ratio of 3:7 to 10:1 used in the polyolefin composition of the present invention is in the range of 15% to 40% by weight, preferably 25% to 40% by weight, more preferably 30% to 40% by weight (based on the total weight of the polymer composition), said blend (A) being recycled from waste plastic material derived from post-consumer waste and / or post-industrial waste.

[0032] According to the present invention, the amount of glass fiber used in the polyolefin composition of the present invention is in the range of 17% to 50% by weight, preferably 20% to 50% by weight, more preferably 20% to 40% by weight, and even more preferably 20% to 30% by weight (based on the total weight of the polymer composition).

[0033] According to the present invention, the amount of at least one coupling agent used in the polyolefin composition of the present invention is in the range of 0.5% by weight to 2.5% by weight, preferably 1% by weight to 2% by weight (based on the total weight of the polymer composition).

[0034] It should be understood that the polyolefin composition may also contain additional additives, and in each of the embodiments described herein, the sum of all components is always 100% by weight.

[0035] According to one embodiment, the polyolefin composition of the present invention comprises:

[0036] a) 30% to 50% by weight (based on the total weight of the polymer composition) of at least one polypropylene homopolymer.

[0037] b) 15% to 40% by weight (based on the total weight of the polymer composition) of a blend (A) comprising recycled plastic material of polypropylene and polyethylene, wherein the melt flow rate (MFR2) of the blend (A) is in the range of 8 g / 10 min to 14 g / 10 min, preferably 10 g / 10 min to 12 g / 10 min.

[0038] c) 17% to 50% by weight, preferably 20% to 50% by weight (based on the total weight of the polymer composition) of glass fiber;

[0039] d) 0.5% to 2.5% by weight (based on the total weight of the polymer composition) of at least one coupling agent, and optionally additional additives, wherein the sum of all components is always 100% by weight.

[0040] In another embodiment, the polyolefin composition of the present invention comprises:

[0041] a1) at least one first polypropylene homopolymer;

[0042] a2) at least one second polypropylene homopolymer;

[0043] At least one first polypropylene homopolymer and at least one second polypropylene homopolymer differ from each other in their melt flow rate MFR2 (230°C, 2.16 kg load, measured according to ISO 1133).

[0044] b) A blend (A) comprising a ratio of polypropylene and polyethylene in a ratio of 3:7 to 10:1 of recycled plastic material, said blend (A) being recycled from waste plastic material derived from post-consumer waste and / or post-industrial waste.

[0045] c) Glass fiber; and

[0046] d) At least one coupling agent.

[0047] Therefore, the polyolefin composition of the present invention can comprise two virgin polypropylene homopolymers with different melt flow rates. This allows for adjustment of the melt flow rate of the final polyolefin composition.

[0048] Such a polyolefin having two virgin polypropylene homopolymers may contain:

[0049] a1) 20% to 40% by weight of the first polypropylene homopolymer;

[0050] a2) 10% to 20% by weight of a second polypropylene homopolymer;

[0051] b) A blend (A) comprising 15% to 40% by weight of recycled plastic material including polypropylene and polyethylene, wherein the melt flow rate (MFR2) of the blend (A) is in the range of 8 g / 10 min to 14 g / 10 min, preferably 10 g / 10 min to 12 g / 10 min, at 230°C and 2.16 kg, as measured according to ISO 1133.

[0052] c) 17% to 50% by weight, preferably 20% to 50% by weight, of glass fiber;

[0053] d) 0.5% to 2.5% by weight of at least one coupling agent; and optionally additional additives, wherein the sum of all components is always 100% by weight.

[0054] In another embodiment, the polyolefin composition of the present invention comprises:

[0055] a1) at least one first polypropylene homopolymer;

[0056] a2) at least one second polypropylene homopolymer;

[0057] a3) At least one third polypropylene homopolymer;

[0058] The at least one first polypropylene homopolymer, at least one second polypropylene homopolymer, and at least one third polypropylene homopolymer differ from each other in their melt flow rate MFR2 (230°C, 2.16 kg load, measured according to ISO 1133).

[0059] b) A blend (A) comprising a ratio of polypropylene and polyethylene in a ratio of 3:7 to 10:1 of recycled plastic material, said blend (A) being recycled from waste plastic material derived from post-consumer waste and / or post-industrial waste.

[0060] c) Glass fiber; and

[0061] d) At least one coupling agent.

[0062] Therefore, the polyolefin composition of the present invention can contain three virgin polypropylene homopolymers with different melt flow rates. This allows for even more precise control of the melt flow rate of the final polyolefin composition.

[0063] Such a polyolefin having three virgin polypropylene homopolymers can contain, and preferably consists of, the following components:

[0064] a1) 15% to 30% by weight of the first polypropylene homopolymer;

[0065] a2) 10% to 20% by weight of a second polypropylene homopolymer;

[0066] a3) 5% to 10% by weight of third polypropylene homopolymer;

[0067] b) A blend (A) comprising 15% to 40% by weight of recycled plastic material containing polypropylene and polyethylene, wherein the melt flow rate (MFR2) of the blend (A) is in the range of 10 g / 10 min to 12 g / 10 min (230 °C, 2.16 kg, measured according to ISO 1133).

[0068] c) 17% to 50% by weight, preferably 20% to 50% by weight, of glass fiber;

[0069] d) 0.5% to 2.5% by weight of at least one coupling agent; and optionally additional additives, wherein the sum of all components is always 100% by weight.

[0070] It should be understood that more than three virgin polypropylene homopolymers, such as four or five, may also be used in the polyolefin compositions of the present invention.

[0071] The polypropylene homopolymer used as the primary polymer in the polyolefin compositions of the present invention is selected from the group consisting of:

[0072] - At least one polypropylene homopolymer (PPH-1) with a melt flow rate MFR2 (230°C, 2.16 kg, measured according to ISO 1133) in the range of 5 g / 10 min to 15 g / 10 min, preferably 5 g / 10 min to 10 g / 10 min, and more preferably 8 g / 10 min;

[0073] - At least one polypropylene homopolymer (PPH-2) with a melt flow rate MFR2 (230°C, 2.16 kg, measured according to ISO 1133) in the range of 10 g / 10 min to 30 g / 10 min, preferably 15 g / 10 min to 25 g / 10 min, and more preferably 20 g / 10 min.

[0074] - At least one polypropylene homopolymer (PPH-3) with a melt flow rate MFR2 (230°C, 2.16 kg, measured according to ISO 1133) in the range of 60 g / 10 min to 100 g / 10 min, preferably 70 g / 10 min to 80 g / 10 min, and more preferably 75 g / 10 min.

[0075] - At least one polypropylene homopolymer (PPH-4) with a melt flow rate MFR2 (230°C, 2.16 kg, measured according to ISO 1133) in the range of 100 g / 10 min to 150 g / 10 min, preferably 110 g / 10 min to 130 g / 10 min, and more preferably 125 g / 10 min.

[0076] - At least one polypropylene homopolymer (PPH-5) with a melt flow rate MFR2 (230°C, 2.16 kg, measured according to ISO 1133) in the range of 600 g / 10 min to 1000 g / 10 min, preferably 700 g / 10 min to 900 g / 10 min, and most preferably 800 g / 10 min.

[0077] - At least one polypropylene homopolymer (PPH-6) with a melt flow rate MFR2 (230°C, 2.16 kg, measured according to ISO 1133) in the range of ≤1.5 g / 10 min, preferably in the range of 0.15 g / 10 min to 0.5 g / 10 min, more preferably in the range of 0.3 g / 10 min to 0.45 g / 10 min, and even more preferably in the range of 0.2 g / 10 min.

[0078] Polypropylene virgin polymer

[0079] The properties and characteristics of different polypropylene homopolymers that can be used in the polyolefin compositions of the present invention are described below.

[0080] Polypropylene homopolymer (PPH-1):

[0081] At least one polypropylene homopolymer (PPH-1) has a melt flow rate MFR2 (230°C, 2.16 kg, measured according to ISO 1133) in the range of 5 g / 10 min to 15 g / 10 min, preferably 5 g / 10 min to 10 g / 10 min, more preferably 8 g / 10 min; and a stiffness above 1300 MPa.

[0082] The polypropylene homopolymer (PPH-1) has a melt temperature of at least 150°C, preferably at least 158°C, and more preferably in the range of 158°C to 167°C, for example, 162°C. The flexural modulus of the polypropylene homopolymer (PPH-1), as measured according to ISO 178, can be at least 500 MPa, preferably at least 1000 MPa, and more preferably in the range of 1200 MPa to 2000 MPa, for example, 1400 MPa.

[0083] Preferred materials for polypropylene homopolymer (PPH-1) are available, in particular, from Borealis AG (Australia) under the trade name HD601CF. Suitable alternative materials are, for example, highly crystalline polypropylene homopolymers as described in WO03 / 031174A2.

[0084] Polypropylene homopolymer (PPH-2):

[0085] At least one polypropylene homopolymer (PPH-2) has a melt flow rate MFR2 (230°C, 2.16 kg, measured according to ISO 1133) in the range of 10 g / 10 min to 30 g / 10 min, preferably 15 g / 10 min to 25 g / 10 min, more preferably 20 g / 10 min; and a stiffness above 1800 MPa.

[0086] The polypropylene homopolymer (PPH-2) is essentially composed of propylene units, that is, based on the weight of the propylene homopolymer (PPH-2), it consists of more than 99.7% by weight, and more preferably at least 99.8% by weight, of propylene units. In a preferred embodiment, only propylene units are detectable in the propylene homopolymer (PPH-2).

[0087] It should be understood that the polypropylene homopolymer (PPH-2) is characterized by a small amount of xylene cold soluble (XCS) fraction. Based on the weight of the polypropylene homopolymer (PPH-2), the polypropylene homopolymer (PPH-2) may have the following xylene cold soluble (XCS) fraction: not more than 4.0 wt%, preferably not more than 3.0 wt%, more preferably not more than 2.5 wt%, for example in the range of 0.1 wt% to 4.0 wt%, preferably in the range of 0.1 wt% to 3.0 wt%, more preferably in the range of 0.1 wt% to 2.5 wt%.

[0088] The heat deflection temperature (HDT) of the polypropylene homopolymer (PPH-2) as measured according to ISO 75-2 can be at least 90°C, preferably at least 100°C, more preferably at least 115°C, for example in the range of 90°C to 160°C, preferably in the range of 100°C to 150°C, more preferably in the range of 115°C to 130°C.

[0089] The Charpy impact strength of polypropylene homopolymer (PPH-2), measured at 23°C according to ISO 179-1eA:2000, is at least 1.0 kJ / m. 2 Preferably at least 2.0 kJ / m 2 For example, at 1.0 kJ / m 2 Up to 10 kJ / m 2 Within the range, preferably within 2.0 kJ / m 2 Up to 5.0 kJ / m 2 Within a certain range, for example, 2.5 kJ / m 2The flexural modulus of the polypropylene homopolymer (PPH-2), as measured according to ISO 178, can be at least 500 MPa, preferably at least 1500 MPa, for example in the range of 500 MPa to 3500 MPa, and more preferably in the range of 1500 MPa to 2500 MPa, for example 2000 MPa.

[0090] Polypropylene homopolymer (PPH-2) may contain a nucleating agent, preferably a polymeric nucleating agent, more preferably an α-nucleating agent, such as a polymeric α-nucleating agent. The α-nucleating agent content of the polypropylene homopolymer (PPH-2) is preferably up to 5.0% by weight. In a preferred embodiment, the polypropylene homopolymer (PPH-2) contains no more than 3000 ppm, more preferably 1 ppm to 2000 ppm, of α-nucleating agent.

[0091] Polypropylene homopolymer (PPH-2) is known and commercially available in the art. A suitable example is HF955MO from Borealis AG.

[0092] Polypropylene homopolymer (PPH-3):

[0093] At least one polypropylene homopolymer (PPH-3) has a melt flow rate MFR2 (230°C, 2.16 kg, measured according to ISO 1133) in the range of 60 g / 10 min to 100 g / 10 min, preferably in the range of 70 g / 10 min to 80 g / 10 min, and even more preferably in the range of 75 g / 10 min; and a stiffness above 1300 MPa.

[0094] The polypropylene homopolymer (PPH-3) is essentially composed of propylene units, that is, based on the weight of the polypropylene homopolymer (PPH-3), it consists of more than 99.7% by weight, and more preferably at least 99.8% by weight, of propylene units. In a preferred embodiment, only propylene units are detectable in the polypropylene homopolymer (PPH-3).

[0095] It should be understood that the polypropylene homopolymer (PPH-3) is characterized by a small amount of xylene cold soluble (XCS) fraction. Based on the weight of the polypropylene homopolymer (PPH-3), the amount of xylene cold soluble (XCS) fraction of the polypropylene homopolymer (PPH-3) may not exceed 4.0 wt%, preferably not exceed 3.5 wt%, for example in the range of 0.1 wt% to 4.0 wt%, preferably in the range of 0.1 wt% to 3.5 wt%.

[0096] The heat distortion temperature (HDT) of the polypropylene homopolymer (PPH-3) as measured according to ISO 75-2 can be at least 50°C, preferably at least 60°C, more preferably at least 75°C, for example in the range of 50°C to 120°C, preferably in the range of 60°C to 100°C, more preferably in the range of 75°C to 90°C.

[0097] The notched impact strength (NIS) of polypropylene homopolymer (PPH-3), measured at 23°C according to ISO 179-1eA, can be at least 0.5 kJ / m. 2 Preferably at least 0.7 kJ / m 2 For example, at 0.5 kJ / m 2 Up to 1.5 kJ / m 2 Within the range, preferably within 0.7 kJ / m 2 Up to 1.3 kJ / m 2 Within a certain range, for example, 1.0 kJ / m 2 The flexural modulus of the polypropylene homopolymer (PPH-3), as measured according to ISO 178, can be at least 500 MPa, preferably at least 1000 MPa, for example in the range of 500 MPa to 2500 MPa, preferably in the range of 1000 MPa to 2000 MPa, for example 1500 MPa.

[0098] When the polypropylene homopolymer (PPH-3) contains an α-nucleating agent, it should be understood that, based on the weight of the polypropylene homopolymer (PPH-3), the polypropylene homopolymer (PPH-3) may contain an α-nucleating agent in an amount up to 5.0% by weight, preferably up to 3000 ppm, for example in the range of 1 ppm to 2000 ppm. However, in a preferred embodiment, the polypropylene homopolymer (PPH-2) does not contain any nucleating agent, i.e., the polypropylene homopolymer (PPH-2) is non-nucleating.

[0099] Polypropylene homopolymer (PPH-3) is known and commercially available in the art. A suitable example is Borealis AG's HJ120UB.

[0100] Polypropylene homopolymer (PPH-4):

[0101] The melt flow rate MFR2 (230°C, 2.16 kg, measured according to ISO 1133) of at least one polypropylene homopolymer (PPH-4) is in the range of 100 g / 10 min to 150 g / 10 min, preferably 110 g / 10 min to 130 g / 10 min, and more preferably 125 g / 10 min.

[0102] The Charpy notched impact strength (NIS) of polypropylene homopolymer (PPH-4), measured at 23°C according to ISO 179-1eA, can be at least 0.5 kJ / m. 2 Preferably at least 0.7 kJ / m 2 For example, at 0.5 kJ / m 2 Up to 1.5 kJ / m 2 Within the range, preferably within 0.7 kJ / m 2 Up to 1.3 kJ / m 2 Within the range, for example, 1.0 kJ / m 2 The flexural modulus of the polypropylene homopolymer (PPH-3), as measured according to ISO 178, can be at least 500 MPa, preferably at least 1000 MPa, for example in the range of 500 MPa to 2500 MPa, preferably in the range of 1000 MPa to 2000 MPa, for example 1550 MPa.

[0103] Polypropylene homopolymer (PPH-4) is known and commercially available in the art. A suitable example is Borealis AG's HK060AE.

[0104] Polypropylene homopolymer (PPH-5):

[0105] The melt flow rate MFR2 (230°C, 2.16 kg, measured according to ISO 1133) of at least one polypropylene homopolymer (PPH-5) is in the range of 600 g / 10 min to 1000 g / 10 min, preferably 700 g / 10 min to 900 g / 10 min, and most preferably 800 g / 10 min.

[0106] The melting temperature of the polypropylene homopolymer (PPH-5) is at least 140°C, preferably at least 150°C, and more preferably in the range of 150°C to 160°C, for example, 158°C.

[0107] Polypropylene homopolymer (PPH-5) is known and commercially available in the art. A suitable example is HL708FB from Borealis AG.

[0108] Polypropylene homopolymer (PPH-6):

[0109] At least one polypropylene homopolymer (PPH-6) has a melt flow rate MFR2 (230°C, 2.16 kg, measured according to ISO 1133) of ≤1.5 g / 10 min, preferably in the range of 0.15 g / 10 min to 0.5 g / 10 min, more preferably in the range of 0.3 g / 10 min to 0.45 g / 10 min, and even more preferably 0.2 g / 10 min; and a stiffness of more than 1300 MPa.

[0110] Typically, the weight-average molecular weight (M) of high molecular weight linear polypropylene homopolymer (PPH-6) is... w The weight-average molecular weight (M) is at least 750 kg / mol. Preferably, the weight-average molecular weight (M) of the high molecular weight linear polypropylene homopolymer (PPH-6) is... w The concentration is in the range of 750 kg / mol to 2000 kg / mol, more preferably in the range of 800 kg / mol to 1500 kg / mol.

[0111] The Charpy notched impact strength (NIS) of polypropylene homopolymer (PPH-6), measured at 23°C according to ISO 179-1eA, can reach 5 kJ / m. 2 Up to 10 kJ / m 2 Within the range, preferably 7 kJ / m 2 The tensile modulus of the polypropylene homopolymer (PPH-6), as measured according to ISO 527-2, can be at least 1000 MPa, preferably at least 1500 MPa, more preferably in the range of 1000 MPa to 2000 MPa, for example 1650 MPa.

[0112] Polypropylene homopolymer (PPH-6) is known and commercially available in the art. A suitable example is BE50 from Borealis AG.

[0113] In yet another preferred embodiment, the polyolefin composition of the present invention may further comprise at least one multiphase polypropylene copolymer in addition to at least one polypropylene homopolymer. The multiphase polypropylene copolymer comprises a polypropylene matrix and an elastomeric copolymer as polymer components.

[0114] In another embodiment, the polyolefin composition of the present invention comprises:

[0115] a1) at least one first polypropylene homopolymer;

[0116] a2) Optionally at least one second polypropylene homopolymer;

[0117] At least one of the first polypropylene homopolymers and optionally at least one of the second polypropylene homopolymers differ from each other in their melt flow rate MFR2 (230°C, 2.16 kg load, measured according to ISO 1133).

[0118] a4) At least one multiphase polypropylene copolymer;

[0119] b) A blend (A) comprising a ratio of polypropylene and polyethylene in a ratio of 3:7 to 10:1 of recycled plastic material, said blend (A) being recycled from waste plastic material derived from post-consumer waste and / or post-industrial waste.

[0120] c) Glass fiber; and

[0121] d) At least one coupling agent.

[0122] Such a polyolefin having one or two virgin polypropylene homopolymers and at least one multiphase polypropylene copolymer may comprise, and preferably consists of, the following components:

[0123] a1) 15% to 30% by weight of the first polypropylene homopolymer;

[0124] a2) Optionally 10% to 20% by weight of a second polypropylene homopolymer;

[0125] a4) 10% to 20% by weight of multiphase polypropylene homopolymer;

[0126] b) 15% to 40% by weight of a blend (A) of recycled plastic material comprising polypropylene and polyethylene, wherein the melt flow rate (MFR2) of the blend (A) is in the range of 10 g / 10 min to 12 g / 10 min (230 °C, 2.16 kg, measured according to ISO 1133).

[0127] c) 20% to 50% by weight of glass fiber;

[0128] d) 0.5% to 2.5% by weight of at least one coupling agent; and optionally additional additives, wherein the sum of all components is always 100% by weight.

[0129] Such multiphase polypropylene copolymers can be:

[0130] - At least one multiphase polypropylene copolymer (PPHeco-1) with a melt flow rate MFR2 (230°C, 2.16 kg, measured according to ISO 1133) in the range of 15 g / 10 min to 20 g / 10 min, preferably 18 g / 10 min.

[0131] Multiphase polypropylene copolymer (PPHeco-1):

[0132] The melt flow rate MFR2 (230°C, 2.16 kg, measured according to ISO 1133) of at least one multiphase polypropylene copolymer (PPHeco-1) is in the range of 15 g / 10 min to 25 g / 10 min, preferably 15 g / 10 min to 20 g / 10 min, and more preferably 18 g / 10 min.

[0133] The notched Charpy impact strength (NIS) of the multiphase polypropylene copolymer (PPHeco-1), measured at 23°C according to ISO 179-1eA, can be at least 20 kJ / m. 2 Preferably at least 30 kJ / m 2For example, at 20 kJ / m 2 Up to 50kJ / m 2 Within the range, preferably within 30 kJ / m 2 Up to 40kJ / m 2 Within the range, for example, 35 kJ / m 2 The flexural modulus of the multiphase polypropylene copolymer (PPHeco-1), as measured according to ISO 178, can be at least 300 MPa, preferably at least 500 MPa, for example in the range of 500 MPa to 1500 MPa, and more preferably in the range of 500 MPa to 1000 MPa, for example 800 MPa.

[0134] Multiphase polypropylene copolymers (PPHeco-1) are known in the art and commercially available. A suitable example is EF015AE from Borealis AG.

[0135] As previously mentioned, the melt flow rate of the polyolefin composition of the present invention can be varied. Therefore, the melt flow rate MFR2 (ISO 1133, 2.16 kg, 230 °C, measured according to ISO 1133) of the polyolefin composition of the present invention can be in the range of 2 g / 10 min to 20 g / 10 min, preferably 3 g / 10 min to 17 g / 10 min, more preferably 5 g / 10 min to 15 g / 10 min, and even more preferably 10 g / 10 min to 15 g / 10 min.

[0136] In one embodiment, the tensile modulus (ISO 527-2) of the polyolefin composition of the present invention is at least 4.0 GPa, preferably at least 4.5 GPa; more preferably at least 5.5 GPa, preferably at least 6 GPa, more preferably at least 6.5 GPa, even more preferably at least 6.8 GPa, particularly in the range of 4 GPa to 14 GPa, and even more particularly in the range of 4.5 GPa to 12 GPa.

[0137] In another embodiment, the impact strength (ISO 179; Charpy 1eA +23°C) of the polyolefin composition of the present invention is at least 5.0 kJ / m². 2 Preferably at least 6.0 kJ / m 2 More preferably at least 7 kJ / m 2 More preferably at least 7.5 kJ / m 2 More preferably at least 8kJ / m 2 Even more preferably at least 8.5 kJ / m 2 Especially at 5.0 kJ / m 2 Up to 12.0 kJ / m 2 Within that range, and more specifically at 5.5 kJ / m 2Up to 10 kJ / m 2 Within the range.

[0138] More specific embodiments of the compositions of the present invention are described below.

[0139] In a first embodiment, a polyolefin composition is provided comprising:

[0140] a1) 30% to 40% by weight (based on the total weight of the polymer composition) of at least one polypropylene homopolymer (PPH-1), wherein the melt flow rate MFR2 (230°C, 2.16 kg, measured according to ISO 1133) of said at least one polypropylene homopolymer (PPH-1) is in the range of 5 g / 10 min to 15 g / 10 min, preferably 5 g / 10 min to 10 g / 10 min, more preferably 8 g / 10 min.

[0141] b) 30% to 40% by weight (based on the total weight of the polymer composition) of a blend (A) comprising recycled plastic material of polypropylene and polyethylene, wherein the melt flow rate (MFR2) of the blend (A) (230°C, 2.16 kg, measured according to ISO 1133) is in the range of 8 g / 10 min to 14 g / 10 min, preferably 10 g / 10 min to 12 g / 10 min.

[0142] c) 17% to 30% by weight, preferably 20% to 30% by weight (based on the total weight of the polymer composition) of glass fiber;

[0143] d) at least one coupling agent in amounts of 1% to 2% by weight (based on the total weight of the polymer composition), and optionally additional additives, wherein the sum of all components is always 100% by weight.

[0144] Such a first polyolefin composition can have:

[0145] - Melt flow rate MFR2 (230°C, 2.16 kg, measured according to ISO 1133) in the range of 2 g / 10 min to 5 g / 10 min; preferably in the range of 3.5 g / 10 min to 5 g / 10 min, more preferably in the range of 4 g / 10 min to 4.5 g / 10 min;

[0146] - A tensile modulus of at least 6 GPa, preferably at least 6.5 GPa, preferably at least 6.7 GPa, more preferably at least 6.8 GPa, and even more preferably at least 6.9 GPa (ISO 527-2), and

[0147] - at least 8kJ / m 2 Preferably at least 8.2 kJ / m 2Preferably at least 8.4 kJ / m 2 More preferably at least 8.5 kJ / m 2 Impact strength (Charges 1eA + 23℃).

[0148] In a second embodiment, a polyolefin composition is provided comprising:

[0149] a1) 30% to 50% by weight of at least one propylene homopolymer (PPH-1), wherein the melt flow rate MFR2 (230°C, 2.16 kg, measured according to ISO 1133) of the at least one propylene homopolymer (PPH-1) is in the range of 6 g / 10 min to 12 g / 10 min, preferably 8 g / 10 min;

[0150] a2) 15% to 20% by weight of at least one propylene homopolymer (PPH-6), wherein the melt flow rate MFR2 (230°C, 2.16 kg, measured according to ISO 1133) of the at least one propylene homopolymer (PPH-6) is ≤1.5 g / 10 min; preferably in the range of 0.15 g / 10 min to 0.5 g / 10 min, more preferably 0.2 g / 10 min;

[0151] b) 25% to 40% by weight of a blend (A) of recycled plastic material comprising polypropylene and polyethylene, wherein the melt flow rate (MFR2) of the blend (A) is in the range of 10 g / 10 min to 12 g / 10 min (230 °C, 2.16 kg, measured according to ISO 1133).

[0152] c) 17% to 30% by weight, preferably 20% to 30% by weight, of glass fiber;

[0153] d) 0.5% to 2.0% by weight, particularly 1% by weight, of at least one coupling agent, and optionally additional additives, wherein the sum of all components is always 100% by weight.

[0154] Such a second polyolefin composition can have:

[0155] - Melt flow rate MFR2 (230°C, 2.16 kg, measured according to ISO 1133) in the range of 2 g / 10 min to 3 g / 10 min, preferably 2 g / 10 min to 2.5 g / 10 min;

[0156] - A tensile modulus of at least 4.5 GPa, preferably at least 4.7 GPa, more preferably at least 4.8 GPa (ISO 527-2), and

[0157] -At least 7kJ / m 2 Preferably at least 7.5 kJ / m2 Preferably at least 7.6 kJ / m 2 More preferably at least 7.8 kJ / m 2 Even more preferably at least 7.9 kJ / m 2 Impact strength (Charges 1eA + 23℃).

[0158] In a third embodiment, a polyolefin composition is provided, comprising:

[0159] a1) 20% to 40% by weight of at least one polypropylene homopolymer (PPH-2), wherein the melt flow rate MFR2 (230°C, 2.16 kg, measured according to ISO 1133) of the at least one polypropylene homopolymer (PPH-2) is in the range of 10 g / 10 min to 30 g / 10 min, preferably 15 g / 10 min to 25 g / 10 min, more preferably 20 g / 10 min;

[0160] a2) 8% to 20% by weight of at least one polypropylene homopolymer (PPH-5), wherein the melt flow rate MFR2 (230°C, 2.16 kg, measured according to ISO 1133) of the at least one polypropylene homopolymer (PPH-5) is in the range of 600 g / 10 min to 1000 g / 10 min, preferably 700 g / 10 min to 900 g / 10 min, and preferably 800 g / 10 min;

[0161] b) 30% to 40% by weight of a blend (A) of recycled plastic material comprising polypropylene and polyethylene, wherein the melt flow rate (MFR2) of the blend (A) is in the range of 10 g / 10 min to 12 g / 10 min (230 °C, 2.16 kg, measured according to ISO 1133).

[0162] c) 17% to 30% by weight, preferably 20% to 30% by weight, of glass fiber;

[0163] d) at least one coupling agent, from 1% to 2.0% by weight, and optionally additional additives, wherein the sum of all components is always 100% by weight.

[0164] Such a third polyolefin composition can have:

[0165] - Melt flow rate MFR2 (230°C, 2.16 kg, measured according to ISO 1133) in the range of 15 g / 10 min to 20 g / 10 min, preferably 17 g / 10 min to 18 g / 10 min;

[0166] - A tensile modulus of at least 6.5 GPa, preferably at least 4.7 GPa, more preferably at least 4.8 GPa (ISO 527-2), and

[0167] - At least 6.0 kJ / m 2 Preferably at least 6.2 kJ / m 2 Impact strength (Charges 1eA + 23℃).

[0168] In the fourth embodiment, a polyolefin composition is provided, comprising:

[0169] a1) 10% to 20% by weight of at least one polypropylene homopolymer (PPH-2), wherein the melt flow rate MFR2 (230°C, 2.16 kg, measured according to ISO 1133) of the at least one polypropylene homopolymer (PPH-2) is in the range of 10 g / 10 min to 30 g / 10 min, preferably 15 g / 10 min to 25 g / 10 min, more preferably 20 g / 10 min;

[0170] a2) 20% to 40% by weight of at least one polypropylene homopolymer (PPH-4), wherein the melt flow rate MFR2 (230°C, 2.16 kg, measured according to ISO 1133) of the at least one polypropylene homopolymer (PPH-4) is in the range of 100 g / 10 min to 150 g / 10 min, preferably 110 g / 10 min to 130 g / 10 min, more preferably 125 g / 10 min;

[0171] b) 30% to 40% by weight of a blend (A) of recycled plastic material comprising polypropylene and polyethylene, wherein the melt flow rate (MFR2) of the blend (A) is in the range of 10 g / 10 min to 12 g / 10 min (230 °C, 2.16 kg, measured according to ISO 1133).

[0172] c) 17% to 30% by weight, preferably 20% to 30% by weight, of glass fiber;

[0173] d) at least one coupling agent, from 1% to 2.0% by weight, and optionally additional additives, wherein the sum of all components is always 100% by weight.

[0174] Such a fourth polyolefin composition can have:

[0175] - Melt flow rate MFR2 (230°C, 2.16 kg, measured according to ISO 1133) in the range of 10 g / 10 min to 15 g / 10 min, preferably 12 g / 10 min to 13 g / 10 min;

[0176] - A tensile modulus of at least 6.5 GPa, preferably at least 4.7 GPa, more preferably at least 4.8 GPa (ISO 527-2), and

[0177] - At least 6.0 kJ / m 2 Preferably at least 6.3 kJ / m 2 Impact strength (Charges 1eA + 23℃).

[0178] In the fifth embodiment, a polyolefin composition is provided, comprising:

[0179] a1) 10% to 20% by weight of at least one polypropylene homopolymer (PPH-2), wherein the melt flow rate MFR2 (230°C, 2.16 kg, measured according to ISO 1133) of the at least one polypropylene homopolymer (PPH-2) is in the range of 10 g / 10 min to 30 g / 10 min, preferably 15 g / 10 min to 25 g / 10 min, more preferably 20 g / 10 min;

[0180] a2) 15% to 30% by weight of at least one polypropylene homopolymer (PPH-3), wherein the melt flow rate MFR2 (230°C, 2.16 kg, measured according to ISO 1133) of the at least one polypropylene homopolymer (PPH-3) is in the range of 60 g / 10 min to 100 g / 10 min, preferably 70 g / 10 min to 80 g / 10 min, more preferably 75 g / 10 min;

[0181] a3) 4% to 10% by weight of at least one propylene homopolymer (PPH-6), wherein the melt flow rate MFR2 (230°C, 2.16 kg, measured according to ISO 1133) of the at least one propylene homopolymer (PPH-6) is ≤1.5 g / 10 min; preferably in the range of 0.15 g / 10 min to 0.5 g / 10 min, more preferably 0.2 g / 10 min;

[0182] b) 25% to 40% by weight of a blend (A) of recycled plastic material comprising polypropylene and polyethylene, wherein the melt flow rate (MFR2) of the blend (A) is in the range of 10 g / 10 min to 12 g / 10 min (230 °C, 2.16 kg, measured according to ISO 1133).

[0183] c) 17% to 20% by weight, preferably 20% to 30% by weight, of glass fiber;

[0184] d) at least one coupling agent, ranging from 1% to 2% by weight; and optionally additional additives, wherein the sum of all components is always 100% by weight.

[0185] Such a fifth polyolefin composition can have:

[0186] - Melt flow rate MFR2 (230°C, 2.16 kg, measured according to ISO 1133) in the range of 5 g / 10 min to 15 g / 10 min, preferably 6 g / 10 min to 10 g / 10 min;

[0187] - A tensile modulus of at least 4 GPa, preferably at least 5 GPa, more preferably at least 6 GPa, and even more preferably at least 6.5 GPa (ISO 527-2), and

[0188] - At least 6.0 kJ / m 2 Preferably at least 7 kJ / m 2 More preferably at least 7.5 kJ / m 2 Impact strength (Charges 1eA + 23℃).

[0189] In the sixth embodiment, a polyolefin composition is provided, comprising:

[0190] a1) 20% to 30% by weight of at least one polypropylene homopolymer (PPH-4), wherein the melt flow rate MFR2 (230°C, 2.16 kg, measured according to ISO 1133) of the at least one polypropylene homopolymer (PPH-4) is in the range of 100 g / 10 min to 150 g / 10 min, preferably 110 g / 10 min to 130 g / 10 min, more preferably 125 g / 10 min;

[0191] a4) 10% to 20% by weight of at least one multiphase polypropylene copolymer (PPHeco-1), wherein the melt flow rate MFR2 (230°C, 2.16 kg, measured according to ISO 1133) of said at least one multiphase polypropylene copolymer (PPHeco-1) is in the range of 15 g / 10 min to 20 g / 10 min, preferably 18 g / 10 min.

[0192] b) A blend (A) comprising 25% to 40% by weight of recycled plastic material containing polypropylene and polyethylene, wherein the melt flow rate (MFR2) of the blend (A) is in the range of 10 g / 10 min to 12 g / 10 min at 230 °C, 2.16 kg, as measured according to ISO 1133.

[0193] c) 17% to 30% by weight, preferably 20% to 30% by weight, of glass fiber;

[0194] d) at least one coupling agent, ranging from 1% to 2% by weight; and optionally additional additives, wherein the sum of all components is always 100% by weight.

[0195] Such a sixth polyolefin composition can have:

[0196] - Melt flow rate MFR2 (230°C, 2.16 kg, measured according to ISO 1133) in the range of 10 g / 10 min to 15 g / 10 min, preferably 12 g / 10 min to 13 g / 10 min;

[0197] - A tensile modulus of at least 4 GPa, preferably at least 4.4 GPa (ISO 527-2), and

[0198] - At least 6.0 kJ / m 2 Preferably at least 7 kJ / m 2 More preferably at least 7.5 kJ / m 2 Impact strength (Charges 1eA + 23℃).

[0199] In the seventh embodiment, a polyolefin composition is provided comprising:

[0200] a1) 10% to 20% by weight of at least one polypropylene homopolymer (PPH-2), wherein the melt flow rate MFR2 (230°C, 2.16 kg, measured according to ISO 1133) of the at least one polypropylene homopolymer (PPH-2) is in the range of 10 g / 10 min to 30 g / 10 min, preferably 15 g / 10 min to 25 g / 10 min, more preferably 20 g / 10 min;

[0201] a2) 10% to 20% by weight of at least one polypropylene homopolymer (PPH-4), wherein the melt flow rate MFR2 (230°C, 2.16 kg, measured according to ISO 1133) of the at least one polypropylene homopolymer (PPH-4) is in the range of 100 g / 10 min to 150 g / 10 min, preferably 110 g / 10 min to 130 g / 10 min, more preferably 125 g / 10 min;

[0202] a4) 8% to 12% by weight of at least one multiphase polypropylene copolymer (PPHeco-1), wherein the melt flow rate MFR2 (230°C, 2.16 kg, measured according to ISO 1133) of said at least one multiphase polypropylene copolymer (PPHeco-1) is in the range of 15 g / 10 min to 20 g / 10 min, preferably 18 g / 10 min.

[0203] b) A blend (A) comprising 25% to 40% by weight of recycled plastic material containing polypropylene and polyethylene, wherein the melt flow rate (MFR2) of the blend (A) is in the range of 10 g / 10 min to 12 g / 10 min at 230 °C, 2.16 kg, as measured according to ISO 1133.

[0204] c) 17% to 30% by weight, preferably 20% to 30% by weight, of glass fiber;

[0205] d) at least one coupling agent, ranging from 1% to 2% by weight; and optionally additional additives, wherein the sum of all components is always 100% by weight.

[0206] Such a seventh polyolefin composition can have:

[0207] - Melt flow rate MFR2 (230°C, 2.16 kg, measured according to ISO 1133) in the range of 5 g / 10 min to 15 g / 10 min, preferably 10 g / 10 min to 13 g / 10 min;

[0208] - A tensile modulus of at least 4 GPa, preferably at least 4.5 GPa (ISO 527-2), and

[0209] - At least 6.0 kJ / m 2 Preferably at least 7 kJ / m 2 More preferably at least 7.2 kJ / m 2 Impact strength (Charges 1eA + 23℃).

[0210] Blend of recycled materials (A)

[0211] The blend (A) is obtained from a recycled waste stream. The blend (A) can be either recycled post-consumer waste or industrial waste, such as from the automotive industry, or alternatively a combination of both. Particularly preferred is that the blend (A) consists of recycled post-consumer waste and / or industrial waste.

[0212] In one aspect, the blend (A) can be a polypropylene (PP)-rich material from recycled plastics, the PP-rich material containing significantly more polypropylene than polyethylene. Polypropylene-rich recycled waste streams can be obtained, for example, from the automotive industry, particularly since some automotive parts, such as bumpers, are sources of fairly pure polypropylene material in recycled streams, or through enhanced sorting. Rich PP material can be obtained through selective treatment, degassing, and filtration, and / or through separation based on type and color (e.g., NIR or Raman sorting and VIS sorting). It can be obtained from domestic waste streams (i.e., products of domestic recycling), for example, from the "yellow bag" recycling system operated by the "Green Dot" organization in some areas of Germany.

[0213] Preferably, the polypropylene-rich recycled material is obtained from recycled waste using plastic recycling processes known in the art. Such PP-rich recycled materials are commercially available from sources such as Corepla (the Italian Consortium for the collection, recovery, and recycling of packaging plastic wastes), Resource Plastics Corp. (Brampton, ON), Kruschitz GmbH, Plasticsand Recycling (AT), Vogt Plastik GmbH (DE), Mtm ​​Plastics GmbH (DE), etc. Non-exhaustive examples of PP-rich recycled materials include: PP (Mtm Plastics GmbH), This invention relates to the recycling of polypropylene granules (Axion Ltd) and polypropylene copolymers (BSP compounds). It is believed that this invention is applicable to a wide range of recycled polypropylene materials or materials or compositions with a high content of recycled polypropylene. The polypropylene-rich recycled material may be in granular form.

[0214] Relative to the total weight of the composition, the PP-rich blend (A) may have the following relative amounts of propylene-derived units: greater than 50% by weight, preferably greater than 53% by weight, more preferably greater than 60% by weight, more preferably greater than 70% by weight, more preferably greater than 75% by weight, more preferably greater than 80% by weight, even more preferably greater than 90% by weight, and even more preferably greater than 95% by weight.

[0215] It should be understood that the PP present in the PP-rich blend is preferably isotactic polypropylene. In one embodiment, the isotactic polypropylene content of the PP-rich blend (A) can be from 50% to 80% by weight relative to the total weight of the blend (A).

[0216] Furthermore, the PP-rich blend (A) may have the following relative amounts of ethylene-derived units: less than 47% by weight, more preferably less than 40% by weight, more preferably less than 30% by weight, more preferably less than 20% by weight, and most preferably less than 10% by weight. Typically, the relative amount of ethylene-derived units is greater than 5% by weight relative to the total weight of the composition. It should be understood that the ethylene present is preferably ethylene derived from polyethylene and copolymers containing ethylene.

[0217] The polyethylene fraction of the recycled material may include recycled high-density polyethylene (rHDPE), recycled medium-density polyethylene (rMDPE), recycled low-density polyethylene (rLDPE), linear low-density polyethylene (LLDPE), and mixtures thereof. In one embodiment, the recycled material has an average density greater than 0.8 g / cm³. 3 Preferably greater than 0.9 g / cm³ 3 The most preferred value is greater than 0.91 g / cm³. 3 High-density PE.

[0218] The blend (A) may also contain polystyrene in the following relative amounts: 0% to 5.0% by weight, preferably 0.5% to 4.0% by weight, more preferably 1.0% to 3.0% by weight, and most preferably 1.5% to 2.5% by weight.

[0219] According to the invention, the limonene content of the blend (A), as determined by solid-phase microextraction (HS-SPME-GC-MS), is from 0.1 ppm to 100 ppm, more preferably from 1 ppm to 50 ppm, and most preferably from 2 ppm to 35 ppm. Limonene is conventionally found in recycled polyolefin materials and originates from packaging applications in the fields of cosmetics, detergents, shampoos, and similar products. Therefore, when the blend (A) contains materials derived from such types of household waste streams, the blend (A) contains limonene.

[0220] Fatty acid content is another indicator of the recovery source of blend (A). However, in some cases, due to special treatment during the recovery process, the fatty acid content may be below the detection limit. According to the present invention, the fatty acid content of blend (A), as determined by solid phase microextraction (HS-SPME-GC-MS), is preferably from 1 ppm to 200 ppm, more preferably from 1 ppm to 150 ppm, more preferably from 2 ppm to 100 ppm, and most preferably from 3 ppm to 80 ppm.

[0221] In a preferred aspect, the blend (A) (i) contains less than 5% by weight, preferably less than 1.5% by weight, of polystyrene; and / or (ii) contains less than 3.5% by weight, preferably less than 1% by weight, of talc; and / or (iii) contains less than 1.0% by weight, preferably less than 0.5% by weight, of polyamide.

[0222] Due to the recycled source, the blend (A) may also contain, relative to the weight of the blend (A), up to 10% by weight, preferably 3% by weight: organic fillers, and / or inorganic fillers, and / or additives.

[0223] Therefore, in one embodiment, the polyolefin composition blend (A) of the recycled plastic material of the present invention comprises:

[0224] A-1) Polypropylene content of 50% to 99% by weight,

[0225] A-2) Polyethylene content of 2% to 40% by weight,

[0226] A-3) 0% to 5.0% by weight of polystyrene and / or copolymers such as ABS,

[0227] A-4) 0% to 3.0% by weight of stabilizer,

[0228] A-5) 0% to 4.0% by weight of polyamide-6,

[0229] A-6) 0% to 3.0% by weight of talc,

[0230] A-7) 0% to 3.0% by weight of chalk,

[0231] A-8) 0% to 1.0% by weight of paper,

[0232] A-9) 0% to 1.0% by weight of timber,

[0233] A-10) 0% to 0.5% by weight of metal,

[0234] A-11) such as limonene from 0.1 ppm to 100 ppm as determined by solid-phase microextraction (HS-SPME-GC-MS), and

[0235] A-12) Total fatty acid content from 0 ppm to 200 ppm, as determined by solid-phase microextraction (HS-SPME-GC-MS).

[0236] All quantities are given relative to the total weight of the blend (A).

[0237] As described above, based on the total weight of blend (A), blend (A) may contain one or more additional components selected from the following:

[0238] A-4) Up to 3.0% by weight of stabilizer, preferably up to 2.0% by weight of stabilizer; A-5) Up to 4.0% by weight of polyamide-6, preferably up to 2.0% by weight of polyamide-6.

[0239] A-6) Up to 3.0% by weight of talc, preferably up to 1.0% by weight of talc.

[0240] A-7) up to 3.0% by weight of chalk, preferably up to 1.0% by weight of chalk.

[0241] A-8) Up to 1.0% by weight of paper, preferably up to 0.5% by weight of paper.

[0242] A-9) Up to 1.0% by weight of wood, preferably up to 0.5% by weight of wood, and A-10) Up to 0.5% by weight of metal, preferably up to 0.1% by weight of metal.

[0243] The melt flow rate (ISO 1133, 2.16 kg, 230°C) of the blend (A) can be from 4 g / 10 min to 20 g / 10 min, preferably from 5 g / 10 min to 15 g / 10 min, and more preferably from 6 g / 10 min to 12 g / 10 min.

[0244] Glass fiber / coupling agent / additive

[0245] As described above, the polyolefin composition according to the invention comprises glass fibers, particularly short glass fibers. The average fiber length of the glass fibers used in the fiber-reinforced composite material is preferably in the range of 2.0 mm to 10.0 mm, more preferably in the range of 2.0 mm to 8.0 mm, even more preferably in the range of 2.0 mm to 6.0 mm, even more preferably in the range of 3.0 mm to 5.5 mm, and even more preferably in the range of 3.5 mm to 5.0 mm.

[0246] Further preferably, the average diameter of the short glass fibers used in the fiber-reinforced composite material is preferably 5 μm to 20 μm, more preferably 8 μm to 18 μm, even more preferably 8 μm to 15 μm, even more preferably 10 μm to 15 μm, preferably 11 μm to 14 μm, preferably 12 μm to 14 μm, more preferably 12.3 μm to 13.7 μm, even more preferably 12.5 μm to 13.5 μm.

[0247] In one preferred embodiment, glass fibers with a fiber length of 3.0 mm to 5.0 mm (average 4.0 mm) and a fiber diameter of 12.3 μm to 13.7 μm (average 13 μm) are used. In another preferred embodiment, glass fibers with a fiber length of 3.5 mm to 5.5 mm (average 4.5 mm) and a fiber diameter of 12 μm to 14 μm (average 13 μm) are used.

[0248] As also mentioned above, the polyolefin composition according to the invention comprises at least one coupling agent. The at least one coupling agent is functionalized polypropylene, particularly maleic anhydride (MAH) functionalized polypropylene. The amount of coupling agent in the polyolefin composition can be from 1% to 2% by weight, for example, 1% by weight or 1.25% by weight.

[0249] In another embodiment, the polyolefin composition may contain additional additives. Examples of additives used in the composition include pigments or dyes (e.g., carbon black), stabilizers (antioxidants), acid stabilizers and / or UV stabilizers, antistatic agents, nucleating agents, and utilization agents (e.g., processing aids). Preferred additives are carbon black, at least one antioxidant, and / or at least one UV stabilizer.

[0250] Typically, based on the weight of the total composition, the amount of these additives ranges from 0% to 5.0% by weight, preferably from 0.01% to 3.0% by weight, more preferably from 0.01% to 2.0% by weight.

[0251] Examples of antioxidants commonly used in this field are sterically hindered phenols (e.g., CAS No. 6683-19-8, also known as Irganox 1010FF). TM Sold by BASF), phosphorus-based antioxidants (e.g., CAS No. 31570-04-4, also known as Hostanox PAR 24(FF)). TM Sold by Clariant or as Irgafos 168(FF) TM Sold by BASF), sulfur-based antioxidants (e.g., CAS No. 693-36-7, as Irganox PS-802FL) TM These antioxidants may be sold by BASF, nitrogen-based antioxidants (e.g., 4,4'-bis(1,1'-dimethylbenzyl)diphenylamine), or antioxidant blends. Preferred antioxidants may be tris(2,4-di-tert-butylphenyl) phosphite and / or octadecyl 3-(3',5'-di-tert-butyl-4-hydroxyphenyl) propionate.

[0252] Antioxidants are also well known in the art. Examples include calcium stearate, sodium stearate, zinc stearate, magnesium oxide and zinc oxide, synthetic hydrotalcite (e.g., SHT, CAS No. 11097-59-9), lactates / esters and lactyl esters, as well as calcium stearate (CAS No. 1592-23-0) and zinc stearate (CAS No. 557-05-1).

[0253] Common anti-blocking agents are natural silica, such as diatomaceous earth (e.g., CAS No. 60676-86-0 (SuperfFloss)). TM ), CAS-No.60676-86-0(SuperFloss E TM ), or CAS-No. 60676-86-0 (Celite499) TM Synthetic silica (e.g., CAS-No.7631-86-9, CAS-No.7631-86-9, CAS-No.7631-86-9, CAS-No.7631-86-9, CAS-No.7631-86-9, CAS-No.7631-86-9, CAS-No.112926-00-8, CAS-No.7631-86-9, or CAS-No.7631-86-9); silicates (e.g., aluminum silicate (high...) Kaolin (CAS-no. 1318-74-7), sodium aluminum silicate (CAS-No. 1344-00-9), calcined kaolin (CAS-No. 92704-41-1), aluminum silicate (CAS-No. 1327-36-2), or calcium silicate (CAS-No. 1344-95-2); synthetic zeolites (e.g., sodium calcium aluminosilicate hydrate (CAS-No. 1344-01-0, CAS-No. 1344-01-0 or sodium calcium aluminosilicate hydrate (CAS-No. 1344-01-0)).

[0254] UV stabilizers are, for example, bis(2,2,6,6-tetramethyl-4-piperidinyl)-sebate (CAS-No. 52829-07-9, Tinuvin 770); 2-hydroxy-4-n-octyloxybenzophenone (CAS-No. 1843-05-6, Chimassorb 81). Preferred UV stabilizers can be low molecular weight UV stabilizers and / or high molecular weight UV stabilizers, such as hexadecyl-3,5-di-tert-butyl-4-hydroxybenzoate, mixtures of esters of 2,2,6,6-tetramethyl-4-piperidinol and higher fatty acids (mainly stearic acid), and / or poly((6-morpholino-s-triazine-2,4-diyl)(1,2,2,6,6-pentamethyl-4-piperidinyl)imino)hexamethylene(1,2,2,6,6-pentamethyl-4-piperidinyl)imino).

[0255] Alpha nucleating agents include sodium benzoate (CAS No. 532-32-1); 1,3:2,4-bis(3,4-dimethylbenzyl)sorbitol (CAS 135861-56-2, Millad 3988). Suitable antistatic agents are, for example, glyceryl esters (CAS No. 97593-29-8) or ethoxylated amines (CAS No. 71786-60-2 or CAS No. 61791-31-9) or ethoxylated amides (CAS No. 204-393-1). These additives are typically added in amounts from 100 ppm to 2000 ppm for each individual component of the polymer.

[0256] It should be understood that the present invention also relates to a method for producing a polyolefin composition as defined herein. The method includes the following steps:

[0257] - Provide a mixture of the following components in the required amounts: the at least first polypropylene homopolymer; optionally the at least one second polypropylene homopolymer, further optionally the at least one third polypropylene homopolymer, or even further optionally the at least one polypropylene multiphase copolymer; the blend (A) of recycled material; glass fiber and the at least one coupling agent;

[0258] - Melt the mixture in an extruder, and

[0259] -Optionally, the obtained polyolefin composition is granulated.

[0260] For the purposes of this invention, any suitable melting and mixing means known in the art can be used for mixing and melting.

[0261] However, the melting and mixing steps are preferably carried out in a mixer and / or blender, a high-shear mixer or a low-shear mixer, a high-speed blender or a twin-screw extruder. Most preferably, the melting and mixing steps are carried out in a twin-screw extruder, such as a co-rotating twin-screw extruder. Such twin-screw extruders are well known in the art, and those skilled in the art will adjust the melting and mixing conditions (e.g., melt temperature, screw speed, etc.) according to the process equipment.

[0262] The polyolefin compositions according to the invention can be used in a wide range of applications, such as in the manufacture of structural products, appliances, automotive products, pipes, membranes, geomembranes, roofing applications, pool liners, packaging, covers, and closures. Additionally, due to the satisfactory tensile properties of the compositions of the invention, they can be used as membranes (thickness of 400 micrometers or less) or as flexible foils (thickness greater than 400 micrometers), such as agricultural geomembranes, roofing applications, and as pool liners. Typically, the compositions described herein are used as the core layer of multilayer sheets (e.g., three-layer geomembrane sheets) in which the outer layer is made of various polyolefin materials.

[0263] Experimental Section

[0264] The following examples illustrate certain aspects and embodiments of the invention as described in the claims. However, those skilled in the art will understand that the following description is merely illustrative and should not be construed as limiting the invention in any way.

[0265] Test methods

[0266] Unless otherwise specified, the following terms and determination methods apply to the above general description of the invention and the following embodiments.

[0267] a) Determination of the contents of isotactic polypropylene (iPP), polystyrene (PS), ethylene, PVC and polyamide-6 in the recycled blends

[0268] Sample preparation

[0269] All calibration samples and analyte samples were prepared in a similar manner on melt-pressed plates. Approximately 2 to 3 g of the analyte compound was melted at 190 °C. Subsequently, a pressure of 60 to 80 bar was applied in a hydraulically heated press for 20 seconds. Next, the sample was cooled to room temperature in a cold press under the same pressure for 40 seconds to control the morphology of the compound. The thickness of the plates was controlled to be 100 to 200 μm (depending on the MFR from the sample) using 2.5 cm × 2.5 cm metal calibration frame plates; two plates were produced in parallel at the same time and under the same conditions. The thickness of each plate was measured before any FTIR measurement; all plates were 100 to 200 μm thick. To control the plate surface and avoid any interference during measurement, all plates were pressed between two sheets of double-sided silicone release paper. In the case of powder samples or heterogeneous compounds, the pressing process was repeated three times by pressing and cutting the sample under the same conditions as previously described to improve homogeneity.

[0270] Spectrometer:

[0271] Use a standard transmission FTIR spectrometer with the following settings, such as the Bruker Vertex 70 FTIR spectrometer:

[0272] 4000cm -1 Up to 400cm -1 spectral range,

[0273] • 6mm aperture

[0274] ·2cm -1 spectral resolution,

[0275] • Features 16 background scans and 16 spectral scans.

[0276] • Interferogram with zero fill factor of 32

[0277] Norton Beer has undergone a strong change.

[0278] Record the spectra and analyze them in Bruker Opus software.

[0279] Calibration sample:

[0280] Since FTIR is a secondary method, several calibration standards are combined to cover the target analytical range, typically as follows:

[0281] • For PA, 0.2% to 2.5% by weight

[0282] • For PS, 0.1% to 5% by weight

[0283] • For PET, 0.2% to 2.5% by weight

[0284] • For PVC, 0.1% to 4% by weight

[0285] For the compounds, the following commercial materials were used: Borealis HC600TF as iPP, Borealis FB3450 as HDPE, and for the target polymers, such as RAMAPET N1S (Indorama Polymer) for PET, and for polyamide 6... B36LN (BASF), Styrolution PS 486N (Ineos) for High Impact Polystyrene (HIPS), and Inovyn PVC 263B (in powder form) for PVC.

[0286] All compounds were prepared on a small scale in a Haake kneader at a temperature below 265°C for less than 10 minutes to avoid degradation. Additional antioxidants, such as Irgafos 168 (3000 ppm), were added to minimize degradation.

[0287] calibration:

[0288] The FTIR calibration principle is the same for all components: the intensity of a specific FTIR band divided by the plate thickness and the passing... 1 H or 13 C solution-state NMR correlates with the amount of components determined by the same plate.

[0289] Each specific FTIR absorption band is chosen because its intensity increases with the amount of component concentration and because it separates from the remaining peaks, regardless of the composition of the calibration standard and the actual sample.

[0290] This methodology is described in the publication by Signoret et al., “Alterations of plastic spectra in MIR and the potential impacts on identification towards recycling”, Resources, Conservation and Recycling journal, 2020, Vol. 161, Article 104980.

[0291] The wavelengths used for each calibration band are:

[0292] For PA, 3300cm -1 ,

[0293] For PS, 1601cm -1 ,

[0294] For PET, 1410cm -1 ,

[0295] For PVC, 615cm -1 ,

[0296] For iPP, 1167cm -1 .

[0297] For each polymer component i, a linear calibration is constructed (based on the linearity of the Beer-Lambert law). The typical linear correlation for such a calibration is given below:

[0298]

[0299] Where x i The fractional quantity (in weight %) of polymer component i.

[0300] E i Absorption intensity (in arbitrary units of absorption) for specific bands associated with the polymer component. These specific bands: for PA, 3300 cm⁻¹ -1 For PS, it is 1601cm. -1 For PET, it is 1410cm. -1 For PVC, it is 615cm. -1 For iPP, it is 1167cm. -1

[0301] d is the thickness of the sample plate.

[0302] A i and B iTwo correlation coefficients determined for each calibration curve

[0303] For C2-rich fractions, no specific separating bands can be found, thus indirectly estimating the C2-rich fractions.

[0304] x 富C2 =100-(x iPP +x PA +x PS +x PET +x EVA +x PVC +x 白垩 +x 滑石 )

[0305] The content of EVA, chalk, and talc is estimated "semi-quantitatively." Therefore, the content of C2-rich components is "semi-quantitative."

[0306] For each calibration standard, as long as it is available, the amount of each component is determined by... 1 H or 13 C solution-state NMR was used as the primary method (besides PA) for determination. NMR measurements were performed on the exact same FTIR plate used to construct the FTIR calibration curves.

[0307] Calibration standards were prepared by blending iPP and HDPE to generate calibration curves. The thickness of the calibration standard film was 300 μm. To quantify the contents of iPP, PS, and PA6 in the samples, quantitative IR spectra were recorded in solid state using a Bruker Vertex 70 FTIR spectrometer. Spectra were recorded on 25 × 25 mm square films with a thickness of 50 μm to 100 μm, prepared by compression molding at 190 °C and 4 mPa to 6 mPa. Standard transmission FTIR spectroscopy was employed using the following method: 4000 cm⁻¹. -1 Up to 400cm -1 Spectral range, 6mm aperture, 2cm -1 Spectral resolution, 16 background scans, 16 spectral scans, 32 interferogram zero fill factor and Norton Beer strong apodization.

[0308] Measured 1167cm in iPP -1 The absorption of the band at the location was measured, and the iPP content was quantified according to the calibration curve (absorption / thickness (in cm) relative to iPP content (in weight %)).

[0309] Measured 1601cm -1 (PS) and 3300cm -1The absorption at (PA6) was measured, and the contents of PS and PA6 were quantified according to the calibration curve (absorption / thickness (in cm) relative to PS and PA contents (in wt%)). The ethylene content was obtained by subtracting the contents of iPP, PS, and PA6 from 100. The analysis was performed using a dual determination method.

[0310] b) The amounts of talc and chalk were measured by thermogravimetric analysis (TGA); experiments were performed using a Perkin Elmer TGA8000. Approximately 10 to 20 mg of material was placed in a platinum dish. The temperature was equilibrated at 50 °C for 10 minutes, then increased to 950 °C at a heating rate of 20 °C / min under nitrogen. The weight loss (WCO2) between approximately 550 °C and 700 °C was designated as CO2 released from CaCO3, and thus the chalk content was assessed as:

[0311] Chalk content = 100 / 44 × WCO2

[0312] The temperature was then reduced to 300°C at a cooling rate of 20°C / min. The gas was then switched to oxygen, and the temperature was raised again to 900°C. The weight loss in this step is designated as carbon black (Wcb). Given the contents of carbon black and chalk, the ash content excluding chalk and carbon black was calculated as follows:

[0313] Ash content = (ash residue) - 56 / 44 × WCO2 - Wcb

[0314] The ash residue was measured by weight percent at 900°C during the first step under nitrogen atmosphere. The estimated ash content was the same as the talc content of the recovered material studied.

[0315] c) Quantity of paper and wood

[0316] Paper and wood are determined using conventional laboratory methods, including grinding, flotation, microscopy, and thermogravimetric analysis (TGA) or flotation techniques.

[0317] d) The amount of metal was determined by X-ray fluorescence (XRF).

[0318] e) The amount of limonene was determined by solid-phase microextraction (HS-SPME-GC-MS). Further details are given below for specific samples.

[0319] f) The total amount of fatty acids was determined by solid-phase microextraction (HS-SPME-GC-MS). Further details are given below for characteristic samples.

[0320] g) Melt flow rate is measured at 230°C or 190°C under a load of 2.16 kg (MFR2), as indicated. Melt flow rate is the amount of polymer extruded in grams over 10 minutes at a temperature of 230°C (or 190°C) under a load of 2.16 kg using a test apparatus standardized to ISO 1133.

[0321] h) Tensile modulus, tensile strength, tensile strain at break, tensile strain at tensile strength, tensile stress at break

[0322] The test specimens were measured after a 96-hour conditioning period (at 23°C and 50% relative humidity).

[0323] The tensile modulus was measured according to ISO 527-2 (crosshead speed = 1 mm / min; 23°C) using injection-molded specimens (dog bone shape, 4 mm thickness) as described in EN ISO 1873-2.

[0324] Tensile strength and tensile strain at break were measured according to ISO 527-2 (crosshead speed = 50 mm / min; 23°C) using injection-molded specimens (dog bone shape, 4 mm thickness) as described in EN ISO 1873-2.

[0325] The tensile strain under tensile strength is determined according to ISO 527-2 using injection-molded specimens (dog bone shape, 4 mm thickness) as described in EN ISO 1873-2 at an elongation rate of 50 mm / min until the specimen breaks.

[0326] For samples with a thickness of 4 mm prepared from compression-formed plates, the tensile stress at break is determined according to ISO 527-2 (crosshead speed = 50 mm / min).

[0327] i) Impact strength is determined as the Charpy impact strength of an 80mm × 10mm × 4mm injection-molded specimen prepared according to EN ISO 1873-2 at +23°C (notched) or +23°C (unnotched) according to ISO 179-1 / 1eU. The specimens are tested after 96 hours according to this standard.

[0328] Several examples a (Comparative Example - CE; Inventive Example - IE) are summarized in Tables 1 to 4 below. For the 20 wt% and 30 wt% GF grades, it can be concluded that the stiffness decreases only after the addition of 25 wt% REC material, and remains at an acceptable level thereafter (compared to the original reference).

[0329] Table 1 relates to polyolefin compositions comprising the following: a propylene homopolymer (PPH-1, MFR2 8 g / 10 min, Tc =112.3℃), a blend of recycled materials (A), glass fiber (GF 1.2), coupling agents and other additives.

[0330] Table 2 describes the properties of polyolefin compositions comprising the following: First polypropylene homopolymer (PPH-1, MFR2 8 g / 10 min, T c =112.3℃), second polypropylene homopolymer (PPH-6, MFR2 is 0.2g / 10min, T c =118.9℃), a blend of recycled materials (A), glass fiber (GF 1.2), coupling agents and other additives.

[0331] Table 3 describes the properties of polyolefin compositions comprising the following: First polypropylene homopolymer (PPH-2, MFR2 20 g / 10 min, T c =129.6℃), second polypropylene homopolymer (PPH-3, MFR2 is 75g / 10min, T c =116.9℃), third polypropylene homopolymer (PPH-6, MFR2 is 0.2g / 10min, T c =118.9℃), a blend of recycled materials (A), glass fiber (GF 1.2), coupling agents and other additives.

[0332] Table 4 describes the properties of polyolefin compositions containing the following: different polypropylene homopolymers (PPH-1 with MFR2 of 8 g / 10 min, PPH-2 with MFR2 of 20 g / 10 min, PPH-3 with MFR2 of 75 g / 10 min, PPH-4 with MFR2 of 125 g / 10 min, PPH-5 with MFR2 of 800 g / 10 min, PPH-6 with MFR2 of 0.2 g / 10 min), multiphase polypropylene copolymers (PPHeco-1 with MFR2 of 18 g / 10 min), blends of recycled materials (A), glass fibers (GF 1.2), coupling agents, and additional additives.

[0333] Glass fiber can be obtained from one of the following suppliers: OC (Owens Corning), PPG / NEG, Johns Manville, 3B, Jushi, Taiwan Glass, Camelyaf, CPIC, Taishan, and can be glass fiber 1.2 (average length 4mm, average diameter 13μm) and glass fiber 4.1 (average length 4.5mm, average diameter 13μm).

[0334] The following additives are used: Antioxidants: AO1 (Irganox 1010FF), AO2 (ARENOX DS), AO3 (IRGAFOS 168FF), AO4; Pigment: CB (Plasblak PE6121, commercially available from Cabot); Coupling agent: SCONATPPP 8112GA (AP1.5 adhesion promoter: maleic anhydride highly functionalized polypropylene).

[0335]

[0336] Table 1: Properties of polyolefin compositions (Comparative Examples CE1 to CE2) comprising a blend (A) of a propylene homopolymer (PPH-1 with MFR2 of 8 g / 10 min) mixed with glass fiber GF 1.2 and a blend (A) of recycled material (Dipolen) according to the present invention, and polyolefin compositions (Inventive Examples IE1 to IE2) comprising a propylene homopolymer (PPH-1 with MFR2 of 8 g / 10 min), recycled material (Dipolen), and glass fiber GF 1.2.

[0337] As can be seen in Table 1, the melt flow rate of the homopolymer-recycled composition according to Example IE is higher than that of the virgin homopolymer (CE-1), but lower than that of the recycled material (CE-2). On the other hand, the tensile modulus of the homopolymer-recycled composition according to Example IE is lower than that of the virgin homopolymer (CE-1), but higher than that of the recycled material (CE-2).

[0338] Therefore, the properties of the homopolymer-recycled composition according to the invention are characterized by a melt flow rate that allows for good processing and a tensile modulus that indicates a stable material.

[0339] Furthermore, the properties of the homopolymer-recycled composition according to the invention fall within the range between those of virgin homopolymers and recycled materials. Therefore, the homopolymer-recycled composition according to the invention has properties similar to those of virgin homopolymers, but contains a certain percentage of recycled materials and thus has a better CO2 footprint.

[0340]

[0341] Table 2: Characteristics of blends (A) containing a first polypropylene homopolymer (PPH-1 with MFR2 of 8 g / 10 min) or a second polypropylene homopolymer (PPH-6 with MFR2 of 0.2 g / 10 min) or recycled material without glass fiber GF 1.2 or having glass fiber GF 1.2 (Comparative Examples CE3 to CE6) and polyolefin compositions (Examples IE2 to IE7) according to the present invention containing a first polypropylene homopolymer (PPH-1 with MFR2 of 8 g / 10 min), a second polypropylene homopolymer (PPH-6 with MFR2 of 0.2 g / 10 min), a blend (A) containing recycled material and glass fiber GF 1.2.

[0342] Table 2 shows (similar to the results in Table 1) that the melt flow rates of the homopolymer-recycled compositions according to Examples IE2 to IE7 are higher than those of the virgin homopolymer (CE-3), but lower than those of the recycled homopolymer (CE-4). On the other hand, the tensile modulus of the homopolymer-recycled compositions according to Examples IE2 to IE4 is lower than that of the virgin homopolymer (CE-3), but higher than that of the recycled homopolymer (CE-4). The results also show the effect of the amount of glass fiber; the more glass fiber added, the higher the tensile modulus (see Examples IE2 to IE4 and IE5 to IE7).

[0343]

[0344] Table 3: Blends (A) containing polypropylene homopolymers (PPH-1 with MFR2 of 8 g / 10 min, PPH-2 with MFR2 of 20 g / 10 min, PPH-3 with MFR2 of 75 g / 10 min, and PPH-6 with MFR2 of 0.2 g / 10 min) or recycled materials (Dipolen) without glass fiber GF 1.2 or with glass fiber GF The polyolefin compositions of 1.2 (comparative examples CE7 to CE10) and the polyolefin compositions according to the present invention comprising a first polypropylene homopolymer (PPH-1 with MFR2 of 8 g / 10 min), a second polypropylene homopolymer (PPH-2 with MFR2 of 20 g / 10 min), a third polypropylene homopolymer (PPH-3 with MFR2 of 75 g / 10 min) or a fourth polypropylene homopolymer (PPH-6 with MFR2 of 0.2 g / 10 min), a blend (A) of recycled material (Dipolen), and glass fiber GF1.2 (inventive examples IE8 to IE11).

[0345] Table 3 shows (similar to previous results) that the melt flow rate of the homopolymer-recycled compositions according to Invention Examples IE8 to IE11 is higher than that of the virgin homopolymer (CE-1). The tensile modulus of the homopolymer-recycled compositions according to the Invention Examples again demonstrates the effect of the amount of glass fiber; the more glass fiber added, the higher the tensile modulus (see IE8 to IE11).

[0346]

[0347] Table 4: A mixture of two polypropylene polymers (PPH-1 with MFR2 of 8 g / 10 min, PPH-3 with MFR2 of 75 g / 10 min, PPH-6 with MFR2 of 0.2 g / 10 min, and PPHHeco-1 with MFR2 of 18 g / 10 min) and glass fiber GF. 1.2 Polyolefin compositions (Comparative Examples CE11 to CE12) of the invention, but without the recycled material (Dipolen) blend (A), and polyolefin compositions (Inventive Examples IE12 to IE15) comprising different polypropylene homopolymers (PPH-1 with MFR2 of 8 g / 10 min, PPH-2 with MFR2 of 20 g / 10 min, PPH-3 with MFR2 of 75 g / 10 min, PPH-4 with MFR2 of 125 g / 10 min, PPH-5 with MFR2 of 800 g / 10 min, PPH-6 with MFR2 of 0.2 g / 10 min) and / or multiphase polypropylene copolymers (PPHeco-1 with MFR2 of 18 g / 10 min), the recycled material (Dipolen) blend (A), and glass fiber GF 1.2.

[0348] The results in Table 4 show that the melt flow rate and tensile modulus of the homopolymer-recycled compositions according to Invention Examples IE12 to IE15 can be adjusted by the type of native polymer added to the composition.

Claims

1. A polyolefin composition comprising: a) at least one polypropylene homopolymer comprising 30% to 50% by weight of the total weight of the polyolefin composition. b) A blend (A) of recycled plastic material comprising polypropylene and polyethylene in a ratio of 3:7 to 10:1, comprising 15% to 40% by weight of the total weight of the polyolefin composition, wherein the blend (A) is recycled from waste plastic material derived from post-consumer and / or post-industrial waste, and wherein the melt flow rate (MFR2) of the blend (A) is in the range of 10 g / 10 min to 12 g / 10 min, as measured according to ISO 1133 at 230°C under a load of 2.16 kg. c) 20% to 50% by weight of glass fiber based on the total weight of the polyolefin composition; d) At least one coupling agent, at a weight of 0.5% to 2.5% by weight of the total weight of the polyolefin composition, and optionally additional additives, wherein the sum of all components is always 100% by weight. The polyolefin composition is characterized by: - Melt flow rate MFR2 measured at 230°C under a 2.16 kg load according to ISO 1133, at least 2 g / 10 min; - Tensile modulus of at least 4 GPa, measured at 23°C according to ISO 527-2, and - At least 5 kJ / m 2 Impact strength measured at 23°C in Charpy 1eA according to ISO 179.

2. The polyolefin composition according to claim 1, characterized in that the polyolefin composition comprises: a1) at least one first polypropylene homopolymer; a2) at least one second polypropylene homopolymer; The at least one first polypropylene homopolymer and the at least one second polypropylene homopolymer differ from each other in terms of their melt flow rate (MFR2) measured at 230°C and under a 2.16 kg load according to ISO 1133.

3. The polyolefin composition according to claim 1, characterized in that the polyolefin composition comprises: a1) at least one first polypropylene homopolymer; a2) at least one second polypropylene homopolymer; a3) At least one third polypropylene homopolymer; The at least one first polypropylene homopolymer, the at least one second polypropylene homopolymer, and the at least one third polypropylene homopolymer differ from each other in terms of their melt flow rate (MFR2) measured at 230°C and under a 2.16 kg load according to ISO 1133.

4. The polyolefin composition according to claim 1, characterized in that the polypropylene homopolymer is selected from the group consisting of: - At least one polypropylene homopolymer PPH-1 with a melt flow rate (MFR2) in the range of 5 g / 10 min to 15 g / 10 min, measured at 230 °C and under a load of 2.16 kg according to ISO 1133; - At least one polypropylene homopolymer PPH-2 with a melt flow rate (MFR2) in the range of 10 g / 10 min to 30 g / 10 min, measured at 230 °C and under a load of 2.16 kg according to ISO 1133. - At least one polypropylene homopolymer PPH-3, with a melt flow rate (MFR2) in the range of 60 g / 10 min to 100 g / 10 min, measured at 230 °C and under a load of 2.16 kg according to ISO 1133. - At least one polypropylene homopolymer PPH-4 with a melt flow rate (MFR2) in the range of 100 g / 10 min to 150 g / 10 min, measured at 230 °C and under a load of 2.16 kg according to ISO 1133. - At least one polypropylene homopolymer PPH-5 with a melt flow rate (MFR2) in the range of 600 g / 10 min to 1000 g / 10 min, measured at 230 °C and under a load of 2.16 kg according to ISO 1133. - At least one polypropylene homopolymer PPH-6 with a melt flow rate (MFR2) ≤ 1.5 g / 10 min measured at 230 °C and under a load of 2.16 kg according to ISO 1133.

5. The polyolefin composition according to claim 4, wherein the melt flow rate (MFR2) of the at least one polypropylene homopolymer PPH-1, measured according to ISO 1133 at 230°C under a load of 2.16 kg, is in the range of 5 g / 10 min to 10 g / 10 min.

6. The polyolefin composition according to claim 4, wherein the melt flow rate (MFR2) of the at least one polypropylene homopolymer PPH-1, measured according to ISO 1133 at 230°C under a load of 2.16 kg, is 8 g / 10 min.

7. The polyolefin composition according to claim 4, wherein the melt flow rate (MFR2) of the at least one polypropylene homopolymer PPH-2, measured according to ISO 1133 at 230°C under a load of 2.16 kg, is in the range of 15 g / 10 min to 25 g / 10 min.

8. The polyolefin composition according to claim 4, wherein the melt flow rate (MFR2) of the at least one polypropylene homopolymer PPH-2, measured according to ISO 1133 at 230°C under a load of 2.16 kg, is 20 g / 10 min.

9. The polyolefin composition according to claim 4, wherein the melt flow rate (MFR2) of the at least one polypropylene homopolymer PPH-3, measured according to ISO 1133 at 230°C under a load of 2.16 kg, is in the range of 70 g / 10 min to 80 g / 10 min.

10. The polyolefin composition according to claim 4, wherein the melt flow rate (MFR2) of the at least one polypropylene homopolymer PPH-3, measured according to ISO 1133 at 230°C under a load of 2.16 kg, is 75 g / 10 min.

11. The polyolefin composition according to claim 4, wherein the melt flow rate (MFR2) of the at least one polypropylene homopolymer PPH-4, measured according to ISO 1133 at 230°C under a load of 2.16 kg, is in the range of 100 g / 10 min to 130 g / 10 min.

12. The polyolefin composition according to claim 4, wherein the melt flow rate (MFR2) of the at least one polypropylene homopolymer PPH-4, measured according to ISO 1133 at 230°C under a load of 2.16 kg, is 125 g / 10 min.

13. The polyolefin composition according to claim 4, wherein the melt flow rate (MFR2) of the at least one polypropylene homopolymer PPH-5, measured according to ISO 1133 at 230°C under a load of 2.16 kg, is in the range of 700 g / 10 min to 900 g / 10 min.

14. The polyolefin composition according to claim 4, wherein the melt flow rate (MFR2) of the at least one polypropylene homopolymer PPH-5, measured according to ISO 1133 at 230°C under a load of 2.16 kg, is 800 g / 10 min.

15. The polyolefin composition according to claim 4, wherein the melt flow rate (MFR2) of the at least one polypropylene homopolymer PPH-6, measured according to ISO 1133 at 230°C under a load of 2.16 kg, is in the range of 0.15 g / 10 min to 0.5 g / 10 min.

16. The polyolefin composition according to claim 4, wherein the melt flow rate (MFR2) of the at least one polypropylene homopolymer PPH-6, measured according to ISO 1133 at 230°C under a load of 2.16 kg, is in the range of 0.3 g / 10 min to 0.45 g / 10 min.

17. The polyolefin composition according to claim 4, wherein the melt flow rate (MFR2) of the at least one polypropylene homopolymer PPH-6, measured according to ISO 1133 at 230°C under a load of 2.16 kg, is 0.2 g / 10 min.

18. The polyolefin composition according to claim 1, characterized in that the polyolefin composition comprises at least one multiphase polypropylene copolymer.

19. The polyolefin composition according to claim 18, characterized in that the multiphase polypropylene copolymer is: - At least one multiphase polypropylene copolymer PPHeco-1, with a melt flow rate (MFR2) in the range of 15 g / 10 min to 25 g / 10 min, measured at 230 °C and under a load of 2.16 kg according to ISO 1133.

20. The polyolefin composition of claim 19, wherein the melt flow rate (MFR2) of the at least one multiphase polypropylene copolymer PPHeco-1, measured according to ISO 1133 at 230°C under a load of 2.16 kg, is in the range of 15 g / 10 min to 20 g / 10 min.

21. The polyolefin composition according to claim 19, wherein the melt flow rate (MFR2) of the at least one multiphase polypropylene copolymer PPHeco-1, measured according to ISO 1133 at 230°C under a load of 2.16 kg, is 18 g / 10 min.

22. The polyolefin composition according to claim 1, characterized in that the melt flow rate MFR2, measured according to ISO 1133 at 230°C under a load of 2.16 kg, is in the range of 2 g / 10 min to 20 g / 10 min.

23. The polyolefin composition according to claim 1, characterized in that the melt flow rate MFR2, measured according to ISO 1133 at 230°C under a load of 2.16 kg, is in the range of 3 g / 10 min to 17 g / 10 min.

24. The polyolefin composition according to claim 1, characterized in that the melt flow rate MFR2, measured according to ISO 1133 at 230°C under a load of 2.16 kg, is in the range of 5 g / 10 min to 15 g / 10 min.

25. The polyolefin composition according to claim 1, characterized in that the melt flow rate MFR2, measured according to ISO 1133 at 230°C under a load of 2.16 kg, is in the range of 10 g / 10 min to 15 g / 10 min.

26. The polyolefin composition according to claim 1, characterized in that the tensile modulus measured according to ISO 527-2 is at least 4.5 GPa.

27. The polyolefin composition according to claim 1, characterized in that the tensile modulus, measured according to ISO 527-2, is at least 5.5 GPa.

28. The polyolefin composition according to claim 1, characterized in that the tensile modulus, measured according to ISO 527-2, is at least 6 GPa.

29. The polyolefin composition according to claim 1, characterized in that the tensile modulus measured according to ISO 527-2 is at least 6.5 GPa.

30. The polyolefin composition according to claim 1, characterized in that the tensile modulus measured according to ISO 527-2 is at least 6.8 GPa.

31. The polyolefin composition according to claim 1, characterized in that the tensile modulus, measured according to ISO 527-2, is in the range of 4 GPa to 14 GPa.

32. The polyolefin composition according to claim 1, characterized in that the tensile modulus, as measured according to ISO 527-2, is in the range of 4.5 GPa to 12 GPa.

33. The polyolefin composition according to claim 1, characterized in that its impact strength, measured at 23°C in Charpy 1eA according to ISO 179-1, is at least 6.0 kJ / m². 2 .

34. The polyolefin composition according to claim 1, characterized in that its impact strength, measured at 23°C in Charpy 1eA according to ISO 179-1, is at least 7 kJ / m². 2 .

35. The polyolefin composition according to claim 1, characterized in that its impact strength, measured at 23°C in Charpy 1eA according to ISO 179-1, is at least 7.5 kJ / m. 2 .

36. The polyolefin composition according to claim 1, characterized in that its impact strength, measured at 23°C in Charpy 1eA according to ISO 179-1, is at least 8 kJ / m². 2 .

37. The polyolefin composition according to claim 1, characterized in that its impact strength, measured at 23°C in Charpy 1eA according to ISO 179-1, is at least 8.5 kJ / m. 2 .

38. The polyolefin composition according to claim 1, characterized in that its impact strength, measured at 23°C in Charpy 1eA according to ISO 179-1, is 5.0 kJ / m. 2 Up to 12.0 kJ / m 2 Within the range.

39. The polyolefin composition according to claim 1, characterized in that its impact strength, measured at 23°C in Charpy 1eA according to ISO 179-1, is 5.5 kJ / m. 2 Up to 10 kJ / m 2 Within the range.

40. The polyolefin composition according to claim 1, characterized in that the glass fiber has a length of 2.0 mm to 10.0 mm and a diameter of 5 μm to 20 μm.

41. The polyolefin composition of claim 40, wherein the length of the glass fiber is in the range of 2.0 mm to 8.0 mm.

42. The polyolefin composition of claim 40, wherein the length of the glass fiber is in the range of 2.0 mm to 6.0 mm.

43. The polyolefin composition of claim 40, wherein the glass fiber has a diameter of 8 μm to 18 μm.

44. The polyolefin composition of claim 40, wherein the glass fiber has a diameter of 8 μm to 15 μm.

45. The polyolefin composition according to claim 1, characterized in that the at least one coupling agent is functionalized polypropylene.

46. ​​The polyolefin composition according to claim 1, characterized in that the at least one coupling agent is maleic anhydride (MAH) functionalized polypropylene.

47. Use of the polyolefin composition according to claim 1 in the manufacture of structural products, appliances, automotive products, pipes, membranes, geomembranes, roofing applications, pool liners, packaging, caps and closures, and in the core layer of multilayer polyolefin sheets or films.

48. An article comprising the polyolefin composition according to claim 1.

49. A method for preparing the polyolefin composition according to claim 1, comprising the following steps: - Provide a mixture of the following components in the required amounts: the at least first polypropylene homopolymer; Optional at least one second polypropylene homopolymer, optional at least one third polypropylene homopolymer, and optional at least one polypropylene multiphase copolymer; the blend (A) of recycled material; glass fiber and at least one coupling agent; - Melt the mixture in an extruder, and - Optionally, the obtained polyolefin composition may be granulated.

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