Polymer compositions containing post consumer

Abstract

The invention relates to a polymer composition P comprising: A: 0.1-50 parts by weight of at least one post-consumer regenerated polymer as component A; b: 50-99.9 parts by weight of at least one post-consumer regenerated vinylarene copolymer as component B, in which the post-consumer regenerated polymer A is dissolved in the vinylarene copolymer B and / or the post-consumer regenerated polymer A is dispersed in the continuous phase of the vinylarene copolymer B in the form of discontinuous phase domains, the discontinuous phase of the post-consumption regenerated polymer A at least comprises the average diameter gt; and a phase domain in the range of 30 nm to < = 5 [mu] m.

Description

Technical Field

[0001] The present invention relates to a polymer composition P comprising at least one post-consumer recycled polymer and at least one post-consumer recycled vinyl aromatic copolymer. It was found that by mixing at least one post-consumer recycled vinyl aromatic copolymer, polymer blends of common post-consumer recycled polymers with good compatibility can be obtained. The present invention also relates to a method for mechanical recycling of post-consumer polymers and the use of post-consumer recycled vinyl aromatic copolymers for improving the compatibility of recycled polymers. Background Art

[0002] Mechanical recycling of polymers is the most important method to ensure a circular economy in the polymer sector. Through appropriate cleaning and compounding, virgin polymers, which are usually based on fossil monomers, can be replaced.

[0003] As is well known, the mechanical properties, thermal properties and flow properties of polymer blends are very poor, even if the individual components have very desirable properties. Specifically, plastic blends have low ductility and poor impact strength, which limits their use to applications with lower requirements. For high-value applications, it is first necessary to separate plastic waste by polymer type. However, the high-purity post-consumer recycled polymers that significantly improve performance are also accompanied by higher separation process costs (reference Utracki, Wilkie "Polymer Blends Handbook", 2nd edition, Springer Science 2014, Vol. 1, p. 126). The recovery method of polymer waste and the polymer composition containing recycled polymer are well known in the art. For example, reference is made to JP 2001-279114A, US 9631078, WO 2019 / 074893, US 7884140, US2014 / 0228518, EP3540009 or EP0543975. Since it is almost impossible to obtain 100% pure post-consumer plastics from economic and technical perspectives, a key step in achieving high-quality post-consumer recycled polymer compositions is good miscibility of the polymer to be recycled with other polymers.

[0004] Miscible or compatible polymer blends are defined in the art as polymer blends that are uniform at the molecular level, i.e., blends whose domain size is comparable to the size of the macromolecular statistical segment (see Utracki, Wilkie "Polymer Blends Handbook", 2nd edition, Springer Science 2014, Vol. 1, p. 20). Therefore, the domain size of miscible blends is only within the range of a few nanometers. Compatible polymer blends typically form domains with a size of <5 nm, while incompatible blends form domain sizes of >30 nm (see Utracki, Wilkie "Polymer Blends Handbook", 2nd edition, Springer Science 2014, Vol. 3, p. 1859).

[0005] The present inventors have surprisingly discovered that polymer blends of post-consumer recycled polymers, despite having a domain size > 30 nm, can exhibit excellent properties as long as the polymer blends contain at least 50% by weight of at least one vinyl aromatic copolymer. Summary of the invention

[0006] Specifically, the present invention relates to a polymer composition P, comprising (or consisting of):

[0007] A: 0.1-50 parts by weight, preferably 1-50 parts by weight, usually 10-50 parts by weight of at least one post-consumer recycled polymer as component A;

[0008] B: 50-99.9 parts by weight, preferably 50-99 parts by weight, usually 50-90 parts by weight of at least one post-consumer recycled vinyl aromatic copolymer as component B, comprising:

[0009] B1: 10% to 100% by weight of at least one thermoplastic vinyl aromatic copolymer B1, comprising:

[0010] B1.1: 1% to 81% by weight of repeating units of styrene and / or styrene derivatives;

[0011] B1.2: 19% to 35% by weight of repeating units of acrylonitrile and / or methacrylonitrile, preferably repeating units of acrylonitrile;

[0012] B1.3: 0% to 80% by weight of repeating units of at least one monomer selected from methyl methacrylate (MMA), maleic anhydride (MA) and N-phenylmaleimide (N-PMI);

[0013] B1.4: 0% to 20% by weight of repeating units of at least one other comonomer different from B1.1, B1.2 and B1.3;

[0014] Wherein, B1.1, B1.2, B1.3 and B1.4 together account for 100% by weight of the thermoplastic vinyl aromatic copolymer B1; and

[0015] B2: 0% to 90% by weight of at least one impact-modified polymer B2;

[0016] Wherein B1 and B2 together account for 100% by weight of the vinyl aromatic copolymer B;

[0017] C: 0-200 parts by weight, preferably 0-150 parts by weight, usually 0-100 parts by weight of a substantially non-post-consumer recycled (virgin) vinyl aromatic copolymer as component C, comprising:

[0018] C1: 10% to 100% by weight of at least one thermoplastic vinyl aromatic copolymer C1, comprising:

[0019] C1.1: 1% to 81% by weight of repeating units of styrene and / or styrene derivatives;

[0020] C1.2: 19% to 35% by weight of repeating units of acrylonitrile and / or methacrylonitrile, preferably repeating units of acrylonitrile;

[0021] C1.3: 0% to 80% by weight of at least one repeating unit of a monomer selected from methyl methacrylate (MMA), maleic anhydride (MA) and N-phenylmaleimide (N-PMI);

[0022] C1.4: 0% to 20% by weight of at least one repeating unit of other comonomers different from C1.1, C1.2 and C1.3;

[0023] wherein C1.1, C1.2, C1.3 and C1.4 together account for 100% by weight of the thermoplastic vinyl aromatic copolymer C1; and

[0024] C2: 0% to 90% by weight of at least one impact-modified polymer C2;

[0025] wherein C1 and C2 together represent 100% by weight of a non-post-consumer recycled (virgin) vinyl aromatic copolymer C; and

[0026] D: 0-10 parts by weight, preferably 0-5 parts by weight, typically 0-3 parts by weight, typically 0.1-3 parts by weight (pbw) of at least one other additive as component D;

[0027] wherein components A, B, C and D together account for 100% by weight of the polymer composition P; and

[0028] wherein post-consumer recycled polymer A is dissolved in vinyl aromatic copolymer B and optionally vinyl aromatic copolymer C, and / or

[0029] wherein the post-consumer recycled polymer A is dispersed in the continuous phase of the vinyl aromatic copolymer B and the optional vinyl aromatic copolymer C in the form of discontinuous phase domains; and

[0030] Therein, the discontinuous phase of post-consumer recycled polymer A comprises at least domains with an average diameter ranging from >30 nm to ≤5 μm, preferably >30 nm to ≤2 μm, more preferably >30 nm to ≤200 nm, and typically >30 nm to ≤100 nm.

[0031] According to the present invention, the term "post-consumer recycled polymer A is dissolved in vinyl aromatic copolymer B and optional vinyl aromatic copolymer C" means that the post-consumer recycled polymer A forms a homogeneous mixture at the molecular level with the vinyl aromatic copolymer B and optional vinyl aromatic copolymer C. None of the copolymers A, B or C form phase domains in the homogeneous mixture. The homogeneous mixture forms a single continuous phase.

[0032] The inventors surprisingly found that by mixing at least one post-consumer recycled vinyl aromatic copolymer component B with a post-consumer recycled polymer component A, a recycled copolymer blend with good compatibility and sufficient properties can be obtained for further use in various high quality applications.

[0033] Without being bound by theory, it is believed that the vinyl aromatic copolymer component B is compatible with various different classes of polymers due to the combination of polar and non-polar moieties within the vinyl aromatic copolymer B and therefore acts as a compatibilizer in the polymer composition P according to the invention. This allows recycling together various polymer components A which are usually not fully compatible but which are usually present in recycled post-consumer waste.

[0034] For the purposes of the present invention, the term "post-consumer recycled polymer" or "post-consumer recycled vinyl aromatic copolymer" refers to a polymer prepared from waste plastic materials, especially from recycled durable goods, usually in a recycling and separation process. The post-consumer recycled polymer (i.e., component A) or the post-consumer recycled vinyl aromatic copolymer (i.e., component B) has been through at least one separate thermal compounding step before the mixing step (e.g., extrusion process, injection molding process, etc.).

[0035] For the purposes of the present invention, "durable goods" or "recycled durable goods" refer to goods that are not rapidly consumed or damaged during use, but are expected to continue to be used and produce long-term utility, especially for three years or more, such as household appliances, machinery, sports equipment, consumer electronics and automobiles. In particular, the term "post-consumer product" or "post-consumer durable goods" refers to products or goods that are collected and recycled after their intended use, especially after their use for three years or more, for example, in the form of waste plastic materials.

[0036] For the purposes of the present invention, the term "non-post-consumer recycled vinyl aromatic copolymer" or "virgin vinyl aromatic copolymer" refers to vinyl aromatic copolymer materials made from geological resources, rather than from existing and especially post-used materials. For the purposes of the present invention, virgin polymer materials refer to polymers made from geological resources such as petroleum, rather than from existing and especially post-used plastic materials.

[0037] The present invention, components A, B, C and D and the polymer composition P are described in further detail below. Post-consumer recycled polymer A

[0038] Post-consumer recycled polymers are generally not a single grade of polymer, but a mixture containing various polymer types in different amounts. According to the present invention, post-consumer recycled polymers that can be used as post-consumer recycled polymer A include polymers selected from the following polymer classes:

[0039] Polyolefins such as polyethylene (PE), polypropylene (PP) and (ethylene / propylene) copolymers, polyamides (PA), polyesters such as polyethylene terephthalate (PET), polycarbonates (PC), thermoplastic polyurethanes (TPU), polyalkyl (meth)acrylates such as polymethyl methacrylate (PMMA), polyvinyl chloride (PVC), polystyrene (PS) and vinyl aromatic copolymers, such as vinyl aromatic-diene copolymers such as styrene-butadiene copolymers (SBC), vinyl aromatic-acrylonitrile copolymers such as styrene-acrylonitrile copolymers (SAN) and α-methylstyrene-acrylonitrile copolymers (AMSAN)), vinyl aromatic-diene-acrylonitrile copolymers such as poly(acrylonitrile-butadiene-styrene) (ABS) or vinyl aromatic-acrylate copolymers such as poly(acrylonitrile-styrene-acrylate) (ASA).

[0040] Preferably, the post-consumer recycled polymer A comprises at least one polymer selected from the following polymer classes: polycarbonate (PC), thermoplastic polyurethane (TPU), polyamide (PA), polyalkyl (meth) acrylate, especially polymethyl methacrylate (PMMA), polyvinyl chloride (PVC), polystyrene (PS) and vinyl aromatic copolymers, such as vinyl aromatic-diene copolymers (such as styrene-butadiene copolymers (SBC)), vinyl aromatic-acrylonitrile copolymers (such as styrene-acrylonitrile copolymers (SAN) and α-methylstyrene-acrylonitrile copolymers (AMSAN)), vinyl aromatic-diene-acrylonitrile copolymers (such as poly (acrylonitrile-butadiene-styrene) (ABS)) or vinyl aromatic-acrylate copolymers (such as poly (acrylonitrile-styrene-acrylate) (ASA)). Particularly preferred non-vinyl aromatic copolymers include polycarbonate (PC), polyamide (PA), thermoplastic polyurethane (TPU), polymethyl methacrylate (PMMA), polyvinyl chloride (PVC). Preferably, the vinyl aromatic copolymer includes polystyrene and vinyl aromatic-acrylonitrile copolymer, such as styrene-acrylonitrile copolymer (SAN), α-methylstyrene-acrylonitrile copolymer (AMSAN).

[0041] Preferably, post-consumer recycled polymer A comprises more than 80% by weight, more preferably 90% to 100% by weight, typically 95% to 100% by weight, based on the total weight of polymer A, of at least one polymer selected from the group consisting of polycarbonate (PC), polyamide (PA), thermoplastic polyurethane (TPU), polyalkyl (meth)acrylate, especially polymethyl methacrylate (PMMA), polyvinyl chloride (PVC), polystyrene (PS) and vinyl aromatic copolymers, such as vinyl aromatic-diene copolymers such as styrene-butadiene copolymers (SBC), vinyl aromatic-acrylonitrile copolymers such as styrene-acrylonitrile copolymers (SAN) and α-methylstyrene-acrylonitrile copolymers (AMSAN)), vinyl aromatic-diene-acrylonitrile copolymers such as poly(acrylonitrile-butadiene-styrene) (ABS) or vinyl aromatic-acrylate copolymers such as poly(acrylonitrile-styrene-acrylate) (ASA).

[0042] Preferably, post-consumer recycled polymer A comprises less than 60 wt%, more preferably 0-40 wt%, typically 0-20 wt%, based on the total weight of polymer A, of at least one polymer selected from polyolefins such as polyethylene (PE), polypropylene (PP) and (ethylene / propylene) copolymers and polyesters such as polyethylene terephthalate (PET).

[0043] Considering the difficulty of polymer separation in the post-consumer recycling process, the recycled polymer A usually comprises at least two polymers selected from the following polymer categories: polyolefins (such as polyethylene (PE), polypropylene (PP) and (ethylene / propylene) copolymers), polyamides (PA), polyesters (such as polyethylene terephthalate (PET), polycarbonate (PC), thermoplastic polyurethane (TPU)), polyalkyl (meth) acrylates (such as polymethyl methacrylate (PMMA)), polyvinyl chloride (PVC), polystyrene (PS) and vinyl aromatic copolymers, such as vinyl aromatic-diene copolymers (such as styrene-butadiene copolymers (SBC)), vinyl aromatic-acrylonitrile copolymers (such as styrene-acrylonitrile copolymers (SAN) and α-methylstyrene-acrylonitrile copolymers (AMSAN)), vinyl aromatic-diene-acrylonitrile copolymers (such as poly(acrylonitrile-butadiene-styrene) (ABS)) or vinyl aromatic-acrylate copolymers (such as poly(acrylonitrile-styrene-acrylate) (ASA)).

[0044] More preferably, the post-consumer recycled polymer A comprises at least two polymers selected from the following polymer classes: polycarbonate (PC), polyamide (PA), thermoplastic polyurethane (TPU), polyalkyl (meth) acrylate, especially polymethyl methacrylate (PMMA), polyvinyl chloride (PVC), polystyrene (PS) and vinyl aromatic copolymers, such as vinyl aromatic-diene copolymers (such as styrene-butadiene copolymers (SBC)), vinyl aromatic-acrylonitrile copolymers (such as styrene-acrylonitrile copolymers (SAN) and α-methylstyrene-acrylonitrile copolymers (AMSAN)), vinyl aromatic-diene-acrylonitrile copolymers (such as poly(acrylonitrile-butadiene-styrene) (ABS)) or vinyl aromatic-acrylate copolymers (such as poly(acrylonitrile-styrene-acrylate) (ASA)).

[0045] In one embodiment, the recycled polymer A comprises at least one polymer, typically at least two polymers, selected from thermoplastic polyurethane (TPU), polymethyl methacrylate (PMMA), polyamide (PA), polycarbonate (PC), α-methylstyrene-acrylonitrile copolymer (AMSAN) and polystyrene (PS).

[0046] The preparation and properties of post-consumer recycled polymer A are well known in the art and described in the literature. The method for preparing the post-consumer recycled polymer A is not limited.

[0047] According to the present invention, a polymer class is a group of polymers having common structural features.

[0048] The recycled polymer A usually contains additives, which are usually used to adjust the properties of the polymer A to improve processability, performance characteristics and / or visual appearance. Examples of such additives include mold release agents, lubricants, flame retardants, colorants, dyes, pigments, fillers, plasticizers, which are generally known in the art and described in the literature (see, for example, "Plastics Additives Handbook", Hans Zweifel, 6th edition, Hanser Publishing House, Munich, 2009).

[0049] In addition, since the recycling process is a process that usually cannot provide 100% pure recycled polymer, the recycled polymer A usually contains impurities, depending on the previous application field of the polymer, including metal parts (such as aluminum), or non-thermoplastic polymers (such as polyurethane foam or elastomer).

[0050] For purposes of the present invention, all additives account for the total weight of post-consumer recycled polymer A, i.e., any weight specification of post-consumer recycled polymer A given herein refers to post-consumer recycled polymer A including polymer A and all optional additives (and / or optional impurities) present therein. Post-consumer recycled vinyl aromatic copolymer B

[0051] According to the present invention, the polymer composition P comprises 50-99.9 parts by weight of at least one post-consumer recycled vinyl aromatic copolymer component B, which comprises (or consists of):

[0052] B1: Based on the total weight of the vinyl aromatic copolymer B, 10% to 100% by weight, preferably 30% to 100% by weight, more preferably 50% to 100% by weight of at least one thermoplastic vinyl aromatic copolymer B1, comprising:

[0053] B1.1: 1% to 81% by weight of repeating units of styrene and / or styrene derivatives;

[0054] B1.2: 19% to 35% by weight of repeating units of acrylonitrile and / or methacrylonitrile, preferably repeating units of acrylonitrile;

[0055] B1.3: 0% to 80% by weight of repeating units of at least one monomer selected from methyl methacrylate (MMA), maleic anhydride (MA) and N-phenylmaleimide (N-PMI);

[0056] B1.4: 0% to 20% by weight of repeating units of at least one other comonomer different from B1.1, B1.2 and B1.3;

[0057] Wherein, B1.1, B1.2, B1.3 and B1.4 together account for 100% by weight of the thermoplastic vinyl aromatic copolymer B1; and

[0058] B2: 0% to 90% by weight, preferably 0% to 70% by weight, more preferably 0% to 50% by weight, of at least one impact-modified polymer B2, based on the total weight of the vinyl aromatic copolymer B;

[0059] Wherein B1 and B2 together account for 100% by weight of the vinyl aromatic copolymer B;

[0060] In one embodiment, the vinyl aromatic copolymer B comprises at least one styrene copolymer and / or α-methylstyrene copolymer, comprising:

[0061] B1.1: 65% to 81% by weight of repeating units of styrene and / or α-methylstyrene, preferably repeating units of styrene, and

[0062] B1.2: 19% to 35% by weight of repeating units of acrylonitrile and / or methacrylonitrile, preferably repeating units of acrylonitrile;

[0063] The total weight percentage of the vinyl aromatic copolymer B is 100%.

[0064] According to one embodiment of the present invention, the vinyl aromatic copolymer B optionally comprises at least one impact-modifying polymer B2, which preferably comprises:

[0065] B2.1: 20% to 90% by weight, preferably 40% to 90% by weight, more preferably 45% to 85% by weight, typically 50% to 80% by weight, based on the total weight of the impact-modified polymer B2, of a graft base of one or more monomers comprising:

[0066] B2.11: 70% to 100% by weight, preferably 75% to 100% by weight, more preferably 80% to 100% by weight, based on the total weight of the graft base B2.1, of at least one conjugated diene, in particular butadiene, and / or at least one C1-C8 alkyl (meth)acrylate, in particular n-butyl acrylate and / or 2-ethylhexyl acrylate;

[0067] B2.12: 0% to 30% by weight, preferably 0% to 25% by weight, preferably 0% to 20% by weight, based on the total weight of the graft base B2.1, of at least one further comonomer selected from the group consisting of styrene, α-methylstyrene, acrylonitrile, methacrylonitrile, methyl methacrylate, maleic anhydride and N-phenylmaleimide, preferably styrene and α-methylstyrene, particularly preferably styrene;

[0068] B2.13: 0% to 10% by weight, preferably 0.01% to 5% by weight, typically 0.02% to 2% by weight, based on the total weight of the graft base B2.1, of one or more multifunctional crosslinking monomers selected from allyl (meth)acrylate, divinylbenzene, diallyl maleate, diallyl fumarate, diallyl phthalate, triallyl cyanurate, triallyl isocyanurate and dicyclopentadienyl acrylate (DCPA), wherein, when component B2.11 is an acrylate (e.g. a C1-C8 alkyl (meth)acrylate), the amount thereof is at least 0.1% by weight;

[0069] B2.2: 10% to 80% by weight, preferably 10% to 60% by weight, more preferably 15% to 55% by weight, typically 20% to 50% by weight, based on the total weight of the impact-modified polymer B2, of at least one graft shell of one or more monomers comprising:

[0070] B2.21: 65% to 95% by weight, preferably 70% to 90% by weight, more preferably 75% to 85% by weight, based on the total weight of the graft shell B2.2, of at least one vinylaromatic monomer, preferably styrene and / or α-methylstyrene, in particular styrene;

[0071] B2.22: 5% to 35% by weight, preferably 10% to 30% by weight, more preferably 15% to 25% by weight, of acrylonitrile and / or methacrylonitrile, preferably acrylonitrile, based on the total weight of the graft shell B2.2; and

[0072] B2.3: 0% to 30% by weight, preferably 0% to 20% by weight, more preferably 0% to 15% by weight, based on the total weight of the impact-modified polymer B2, of at least one other component selected from:

[0073] at least one monoethylenically unsaturated monomer selected from the group consisting of methyl methacrylate, maleic anhydride and N-phenylmaleimide, preferably methyl methacrylate, and / or

[0074] At least one molecular weight regulator, especially a mercaptan-based molecular weight regulator, such as tert-dodecyl mercaptan.

[0075] In a preferred embodiment, the impact-modifying polymer B2 is selected from poly(acrylonitrile-butadiene-styrene) (ABS) and poly(acrylonitrile-styrene-acrylate) (ASA) and mixtures thereof.

[0076] In one embodiment, the impact-modified polymer B2 according to the present invention is an ABS vinyl aromatic copolymer comprising:

[0077] B2.1: Based on the total weight of the impact-modified polymer B2, 40% to 90% by weight of a graft base, comprising:

[0078] B2.11: 70% to 100% by weight, preferably 90% to 99.9% by weight, of butadiene, based on the total weight of the graft base (B2.1);

[0079] B2.12: 0% to 30% by weight, preferably 1% to 10% by weight, of styrene, based on the total weight of the graft base (B2.1); and

[0080] B2.2: 10% to 60% by weight of a graft shell, based on the total weight of the impact-modified polymer B2, comprising:

[0081] B2.21: 65% to 95% by weight of styrene, based on the total weight of the graft shell (B2.2);

[0082] B2.22: 5% to 35% by weight of acrylonitrile, based on the total weight of the graft shell (B2.2), and

[0083] B2.3: 0% to 30% by weight of MMA and / or tert-dodecyl mercaptan, based on the total weight of the impact-modified polymer B2.

[0084] In another alternative embodiment, the impact-modified polymer B2 according to the invention is an ASA vinyl aromatic copolymer comprising:

[0085] B2.1: Based on the total weight of the impact-modified polymer B2, 40% to 90% by weight of a graft base, comprising:

[0086] B2.11: 70% to 99.9% by weight, preferably 90% to 99.5% by weight, based on the total weight of the graft base (B2.1), of at least one C1-C8 alkyl (meth)acrylate, preferably n-butyl acrylate and / or 2-ethylhexyl acrylate, in particular n-butyl acrylate;

[0087] B2.12: 0% to 30% by weight, preferably 1% to 10% by weight, of styrene, based on the total weight of the graft base (B2.1);

[0088] B2.13: 0.5% to 5% by weight, preferably 0.1% to 5% by weight, especially 0.5% to 3% by weight, most preferably 1% to 2.5% by weight, based on the total weight of the graft base (B2.1), of one or more multifunctional crosslinking monomers selected from the group consisting of allyl (meth)acrylate, divinylbenzene, diallyl maleate, diallyl fumarate, diallyl phthalate, triallyl cyanurate, triallyl isocyanurate and dicyclopentadienyl acrylate (DCPA), preferably selected from the group consisting of allyl (meth)acrylate and DCPA, especially DCPA, and

[0089] B2.2: 10% to 60% by weight of a graft shell, based on the total weight of the impact-modified polymer B2, comprising:

[0090] B2.21: 65% to 95% by weight of styrene, based on the total weight of the graft shell (B2.2);

[0091] B2.22: 5% to 35% by weight of acrylonitrile, based on the total weight of the graft shell (B2.2); and

[0092] B2.3: 0% to 30% by weight of MMA, based on the total weight of the impact-modified polymer B2.

[0093] In one embodiment of the present invention, the post-consumer recycled vinyl aromatic copolymer component B comprises 80% to 100% by weight of at least one thermoplastic vinyl aromatic copolymer B1, based on the total weight of the vinyl aromatic copolymer component B. Typically, the post-consumer recycled vinyl aromatic copolymer component B comprises less than 5% by weight of the impact-modifying polymer B2, typically less than 1% by weight, such as less than 0.1% by weight, based on the total weight of the vinyl aromatic copolymer component B.

[0094] In a preferred embodiment, the post-consumer recycled vinyl aromatic copolymer component B is selected from styrene-acrylonitrile copolymers, blends of at least one styrene-acrylonitrile copolymer and a mixture of poly(acrylonitrile-butadiene-styrene) (ABS) or poly(acrylonitrile-styrene-acrylate) (ASA), and mixtures thereof.

[0095] The post-consumer recycled copolymer B typically comprises additives, which are typically used to adjust the properties of the copolymer B to improve processability, performance characteristics and / or visual appearance. Examples of such additives include mold release agents, lubricants, flame retardants, colorants, dyes, pigments, fillers, plasticizers, which are generally known in the art and described in the literature (see, for example, "Plastics Additives Handbook", Hans Zweifel, 6th edition, Hanser Publishing House, Munich, 2009).

[0096] For purposes of the present invention, all additives account for the total weight of post-consumer recycled copolymer B, i.e., any weight specification of post-consumer recycled copolymer B given herein refers to post-consumer recycled polymer B including polymer B and all optional additives (and / or optional impurities) present therein. Non-post-consumer recycled vinyl aromatic copolymer C

[0097] The polymer composition P optionally further comprises a vinyl aromatic copolymer C which does not originate from post-consumer recycling. Vinyl aromatic copolymers C are also called virgin vinyl aromatic copolymers C and are usually obtained from fossil resources.

[0098] According to the present invention, the polymer composition P may further comprise 0 to 200 parts by weight of at least one native vinyl aromatic copolymer component C comprising:

[0099] C1: based on the total weight of the vinyl aromatic copolymer C, 10% to 100% by weight, preferably 30% to 100% by weight, more preferably 50% to 100% by weight of at least one thermoplastic vinyl aromatic copolymer C1, comprising:

[0100] C1.1: 1% to 81% by weight of repeating units of styrene and / or styrene derivatives;

[0101] C1.2: 19% to 35% by weight of repeating units of acrylonitrile and / or methacrylonitrile, preferably repeating units of acrylonitrile;

[0102] C1.3: 0% to 80% by weight of at least one repeating unit of a monomer selected from methyl methacrylate (MMA), maleic anhydride (MA) and N-phenylmaleimide (N-PMI);

[0103] C1.4: 0% to 20% by weight of at least one repeating unit of other comonomers different from C1.1, C1.2 and C1.3;

[0104] wherein C1.1, C1.2, C1.3 and C1.4 together account for 100% by weight of the thermoplastic vinyl aromatic copolymer C1; and

[0105] C2: 0% to 90% by weight, preferably 0% to 70% by weight, more preferably 0% to 50% by weight, of at least one impact-modifying polymer C2, based on the total weight of the vinyl aromatic copolymer C;

[0106] The total weight percentage of C1 and C2 is 100% of the vinyl aromatic copolymer C.

[0107] In one embodiment, the vinyl aromatic copolymer C comprises at least one styrene copolymer and / or α-methylstyrene copolymer, comprising:

[0108] C1.1: 65% to 81% by weight of repeating units of styrene and / or α-methylstyrene, preferably repeating units of styrene; and

[0109] C1.2: 19% to 35% by weight of repeating units of acrylonitrile and / or methacrylonitrile, preferably repeating units of acrylonitrile;

[0110] The total weight percentage of the vinyl aromatic copolymer C is 100%.

[0111] According to one embodiment of the present invention, the vinyl aromatic copolymer C optionally comprises at least one impact-modifying polymer C2, which preferably comprises:

[0112] C2.1: 20% to 90% by weight, preferably 40% to 90% by weight, more preferably 45% to 85% by weight, typically 50% to 80% by weight, based on the total weight of the impact-modified polymer C2, of a graft base of one or more monomers comprising:

[0113] C2.11: 70% to 100% by weight, preferably 75% to 100% by weight, more preferably 80% to 100% by weight, based on the total weight of the graft base C2.1, of at least one conjugated diene, in particular butadiene, and / or at least one C1-C8 alkyl (meth)acrylate, in particular n-butyl acrylate and / or 2-ethylhexyl acrylate;

[0114] C2.12: 0% to 30% by weight, preferably 0% to 25% by weight, preferably 0% to 20% by weight, based on the total weight of the graft base C2.1, of at least one further comonomer selected from the group consisting of styrene, α-methylstyrene, acrylonitrile, methacrylonitrile, methyl methacrylate, maleic anhydride and N-phenylmaleimide, preferably styrene and α-methylstyrene, particularly preferably styrene;

[0115] C2.13: 0% to 10% by weight, preferably 0.01% to 5% by weight, typically 0.02% to 2% by weight, based on the total weight of the graft base C2.1, of one or more multifunctional crosslinking monomers selected from the group consisting of allyl (meth)acrylate, divinylbenzene, diallyl maleate, diallyl fumarate, diallyl phthalate, triallyl cyanurate, triallyl isocyanurate and dicyclopentadienyl acrylate (DCPA), wherein, when component C2.11 is an acrylate (e.g. a C1-C8 alkyl (meth)acrylate), the amount thereof is at least 0.1% by weight;

[0116] C2.2: 10% to 80% by weight, preferably 10% to 60% by weight, more preferably 15 to 55% by weight, typically 20 to 50% by weight, based on the total weight of the impact-modified polymer C2, of at least one graft shell of one or more monomers comprising:

[0117] C2.21: 65% to 95% by weight, preferably 70% to 90% by weight, more preferably 75% to 85% by weight, based on the total weight of the graft shell C2.2, of at least one vinylaromatic monomer, preferably styrene and / or α-methylstyrene, in particular styrene;

[0118] C2.22: 5% to 35% by weight, preferably 10% to 30% by weight, more preferably 15% to 25% by weight, of acrylonitrile and / or methacrylonitrile, preferably acrylonitrile, based on the total weight of the graft shell C2.2; and

[0119] C2.3: 0% to 30% by weight, preferably 0% to 20% by weight, more preferably 0% to 15% by weight, based on the total weight of the impact-modified polymer C2, of at least one other component selected from:

[0120] at least one monoethylenically unsaturated monomer selected from the group consisting of methyl methacrylate, maleic anhydride and N-phenylmaleimide, preferably methyl methacrylate, and / or

[0121] At least one molecular weight regulator, especially a mercaptan-based molecular weight regulator, such as tert-dodecyl mercaptan.

[0122] In a preferred embodiment, the impact-modifying polymer C2 is selected from poly(acrylonitrile-butadiene-styrene) (ABS) and poly(acrylonitrile-styrene-acrylate) (ASA) and mixtures thereof.

[0123] In one embodiment, the impact-modified polymer C2 according to the present invention is an ABS vinyl aromatic copolymer comprising:

[0124] C2.1: Based on the total weight of the impact-modified polymer C2, 40% to 90% by weight of a graft base, comprising:

[0125] C2.11: 70% to 100% by weight, preferably 90% to 99.9% by weight, of butadiene, based on the total weight of the graft base (C2.1);

[0126] C2.12: 0% to 30% by weight, preferably 1% to 10% by weight, of styrene, based on the total weight of the graft base (C2.1); and

[0127] C2.2: 10% to 60% by weight of a graft shell, based on the total weight of the impact-modified polymer C2, comprising:

[0128] C2.21: 65% to 95% by weight of styrene, based on the total weight of the graft shell (C2.2);

[0129] C2.22: 5% to 35% by weight of acrylonitrile, based on the total weight of the graft shell (C2.2), and

[0130] C2.3: 0% to 30% by weight of MMA and / or tert-dodecyl mercaptan, based on the total weight of the impact-modified polymer C2.

[0131] In another alternative embodiment, the impact-modifying polymer C2 according to the invention is an ASA vinyl aromatic copolymer comprising:

[0132] C2.1: Based on the total weight of the impact-modified polymer C2, 40% to 90% by weight of a graft base, comprising:

[0133] C2.11: 70% to 99.9% by weight, preferably 90% to 99.5% by weight, based on the total weight of the graft base (C2.1), of at least one C1-C8 alkyl (meth)acrylate, preferably n-butyl acrylate and / or 2-ethylhexyl acrylate, in particular n-butyl acrylate;

[0134] C2.12: 0% to 30% by weight, preferably 1% to 10% by weight, of styrene, based on the total weight of the graft base (C2.1);

[0135] C2.13: Based on the total weight of the graft base (C2.1), 0.5%-5% by weight, preferably 0.1%-5% by weight, especially 0.5%-3% by weight, most preferably 1%-2.5% by weight of one or more multifunctional crosslinking monomers selected from: allyl (meth)acrylate, divinylbenzene, diallyl maleate, diallyl fumarate, diallyl phthalate, triallyl cyanurate, triallyl isocyanurate and dicyclopentadienyl acrylate (DCPA), preferably selected from allyl (meth)acrylate and DCPA, especially DCPA.

[0136] C2.2: 10% to 60% by weight of a graft shell, based on the total weight of the impact-modified polymer C2, comprising:

[0137] C2.21: 65% to 95% by weight of styrene, based on the total weight of the graft shell (C2.2);

[0138] C 2.22: 5% to 35% by weight of acrylonitrile, based on the total weight of the graft shell (C2.2); and

[0139] C 2.3: 0% to 30% by weight of MMA, based on the total weight of the impact-modified polymer C2.

[0140] In one embodiment of the present invention, the vinyl aromatic copolymer component C comprises 80% to 100% by weight of at least one thermoplastic vinyl aromatic copolymer C1, based on the total weight of the vinyl aromatic copolymer component C. Typically, based on the total weight of the vinyl aromatic copolymer component C, the vinyl aromatic copolymer component C comprises less than 5% by weight of the impact-modifying polymer C2, typically less than 1% by weight, for example less than 0.1% by weight.

[0141] In a preferred embodiment, the non-post-consumer recycled (virgin) vinyl aromatic copolymer component C generally contains additives, which are generally used to adjust the properties of the vinyl aromatic copolymer C to improve processability, performance characteristics and / or visual appearance. Examples of such additives include mold release agents, lubricants, flame retardants, colorants, dyes, pigments, fillers, plasticizers, which are generally known in the art and described in the literature (see, for example, "Plastics Additives Handbook", Hans Zweifel, 6th edition, Hanser Publishing House, Munich, 2009).

[0142] For the purposes of the present invention, all additives account for the total weight of the non-post-consumer recycled (virgin) vinyl aromatic copolymer C, i.e., any weight specification of the non-post-consumer recycled (virgin) vinyl aromatic copolymer C given herein refers to the vinyl aromatic copolymer C including the vinyl aromatic copolymer C and all optional additives (and / or optional impurities) present therein.

[0143] Methods for preparing non-post-consumer recycled (virgin) vinyl aromatic copolymers C are known in the art and are described, for example, by Maul et al. in "Polystyrene and Styrene Copolymers" in Ullmann's Encyclopedia of Industrial Chemistry, Wiley-VCH Verlag GmbH & Co. KGaA, 2005. Additive component D

[0144] The polymer composition P may optionally comprise at least one further additive component D in an amount of up to 10 parts by weight.

[0145] Suitable additives D include all substances which are usually used for processing or finishing polymers (see, for example, “Plastics Additives Handbook”, Hans Zweifel, 6th edition, Hanser Verlag, Munich, 2009).

[0146] Preferred additives D include stabilizers (such as UV stabilizers), retardants, antioxidants, thermal and photodecomposition inhibitors, lubricants and dyes.

[0147] These additives D may be mixed at any stage of the preparation process, but are preferably mixed at an early stage in order to benefit from the stabilizing effect (or other specific effect) of the added substance as early as possible.

[0148] Suitable antioxidants are, for example, one or more compounds selected from monophosphite antioxidants, diphosphite antioxidants and sterically hindered phenolic antioxidants. If one or more antioxidants are present, they are preferably selected from monophosphite antioxidants (such as trisubstituted monophosphite derivatives), diphosphite antioxidants (such as substituted pentaerythritol diphosphite derivatives), and sterically hindered phenolic antioxidants (such as 2,6-di-tert-butylphenol derivatives).

[0149] Suitable lubricants / glidants and mold release agents include stearic acid, stearyl alcohol, stearic acid esters, amide waxes (bisstearamide, especially vinyl bisstearamide), polyolefin waxes and / or generally higher fatty acids, their derivatives and corresponding fatty acid mixtures containing 12 to 30 carbon atoms.

[0150] Suitable dyes are any dyes that can be used for transparent, semi-transparent or opaque coloring of polymers, especially those dyes that are suitable for the coloring of styrene copolymers. Such dyes are well known to those skilled in the art. Suitable pigments include titanium dioxide, phthalocyanine, ultramarine blue, iron oxide or carbon black, and all types of organic pigments. In one embodiment, pigment is not used as additive D.

[0151] Examples of optional fillers can be selected from particulate fillers or reinforcing agents, including silicates, amorphous silica, calcium silicates, such as wollastonite, quartz powder, mica, metal oxides, metal hydroxides, carbon black, graphite, barium sulfate, calcium carbonate, magnesium carbonate, bentonite, talc, kaolin, carbon fibers or glass fiber fabrics, glass mats, or glass yarn rovings, chopped glass or glass beads. In one embodiment, no filler is used as additive D.

[0152] Examples of oxidation retarders and thermal stabilizers are halides of metals of Group I of the Periodic Table of the Elements, exemplified by sodium, potassium and / or lithium halides, optionally in combination with copper(I) halides, such as chlorides, bromides, iodides, sterically hindered phenols, hydroquinone, various substitutions of these groups, and mixtures thereof.

[0153] Examples of suitable stabilizers for combating the effects of light (eg UV stabilizers) are various substituted resorcinols, salicylates, benzotriazoles, benzophenones and HALS (hindered amine light stabilizers), such as the commercially available Polymer composition P

[0154] The polymer composition P of the present invention comprises at least 0.1 to 50 parts by weight of at least one post-consumer recycled polymer as component A and 50 to 99.9 parts by weight of at least one post-consumer recycled vinyl aromatic copolymer as component B as defined above;

[0155] wherein post-consumer recycled polymer A is dissolved in vinyl aromatic copolymer B and optionally vinyl aromatic copolymer C, and / or

[0156] The post-consumer recycled polymer A is dispersed in the continuous phase of the vinyl aromatic copolymer B and the optional vinyl aromatic copolymer C in the form of discontinuous phase domains, and the discontinuous phase of the post-consumer recycled polymer A at least includes domains with an average diameter in the range of >30nm to ≤5μm, preferably >30nm to ≤2μm, more preferably >30nm to ≤200nm, and usually >30nm to ≤100nm.

[0157] According to a preferred embodiment of the present invention, the post-consumer recycled polymer A is dispersed in the continuous phase of the vinyl aromatic copolymer B and the optional vinyl aromatic copolymer C in the form of discontinuous phase domains, and the discontinuous phase of the post-consumer recycled polymer A comprises:

[0158] (i) domains with an average diameter in the range of >30 nm to ≤5 μm, preferably >30 nm to ≤2 μm, more preferably >30 nm to ≤200 nm, typically >30 nm to ≤100 nm, and

[0159] (ii) optionally phase domains having an average diameter in the range of >0.1 nm to ≤30 nm.

[0160] In a preferred embodiment of the present invention, post-consumer recycled polymer A and post-consumer recycled vinyl aromatic polymer B are selected from different polymer classes. Vinyl aromatic copolymer B and vinyl aromatic copolymer C may be the same or different from each other, for example, vinyl aromatic copolymer B and vinyl aromatic copolymer C may be selected from the same polymer class or from different polymer classes. In one embodiment, vinyl aromatic copolymer B and vinyl aromatic copolymer C are selected from the same polymer class. In an alternative embodiment, vinyl aromatic copolymer B and vinyl aromatic copolymer C are selected from different polymer classes. Suitable polymer classes are as defined above.

[0161] In one embodiment, the polymer composition P comprises at least two different polymer species as post-consumer recycled polymer A. In a preferred embodiment, the post-consumer recycled polymer A comprises at least two different polymer species other than the post-consumer recycled vinyl aromatic polymer B.

[0162] Preferred embodiments of the present invention include a polymer composition P as described herein, comprising:

[0163] (a) at least one PMMA as component A and at least one SAN as component B;

[0164] (b) at least one PMMA as component A and at least one ABS as component B;

[0165] (c) at least one PMMA as component A and at least one ASA as component B;

[0166] (d) at least one TPU as component A and at least one SAN as component B;

[0167] (e) at least one TPU as component A and at least one ABS as component B;

[0168] (f) at least one TPU as component A and at least one ASA as component B;

[0169] (g) at least one AMSAN as component A and at least one SAN as component B;

[0170] (h) at least one AMSAN as component A and at least one ABS as component B;

[0171] (i) at least one AMSAN as component A and at least one ASA as component B;

[0172] (j) at least one PC as component A and at least one SAN as component B;

[0173] (k) at least one PC as component A and at least one ABS as component B;

[0174] (1) at least one PC as component A and at least one ASA as component B;

[0175] (m) at least one PA as component A and at least one SAN as component B;

[0176] (n) at least one PA as component A and at least one ABS as component B;

[0177] (o) at least one PA as component A and at least one ASA as component B;

[0178] or a combination of the above.

[0179] In one embodiment, the polymer composition P comprises:

[0180] (a) at least one PMMA as component A and at least one SAN as component B;

[0181] (d) at least one TPU as component A and at least one SAN as component B;

[0182] (g) at least one AMSAN as component A and at least one SAN as component B;

[0183] (j) at least one PC as component A and at least one SAN as component B;

[0184] (m) at least one PA as component A and at least one SAN as component B;

[0185] or a combination of the above. Recycling methods

[0186] The present invention also relates to a method for mechanical recycling of post-consumer recycled polymer A, wherein the method comprises the following method steps:

[0187] (i) providing at least one post-consumer recycled polymer A;

[0188] (ii) providing at least one (post-consumer recycled) vinyl aromatic copolymer B;

[0189] (iii) optionally providing at least one non-post-consumer recycled vinyl aromatic copolymer C;

[0190] (iv) optionally providing other additives D;

[0191] (v) melt mixing 0.1-50 parts by weight, preferably 1-50 parts by weight of at least one post-consumer recycled polymer A, 50-99.9 parts by weight, preferably 50-99 parts by weight of at least one post-consumer recycled vinyl aromatic copolymer B and optionally 0-200 parts by weight of a substantially non-post-consumer recycled vinyl aromatic copolymer C, and optionally 0-10 parts by weight of at least one other additive component D;

[0192] (vi) extruding the molten mixture obtained in process step (v);

[0193] Wherein, post-consumer recycled polymer A comprises at least one polymer selected from the following: polyolefins (such as polyethylene (PE), polypropylene (PP) and (ethylene / propylene) copolymers), polyamides (PA), polyesters (such as polyethylene terephthalate (PET)), polycarbonates (PC), thermoplastic polyurethanes (TPU), polyalkyl (meth) acrylates (such as polymethyl methacrylate (PMMA)), polyvinyl chloride (PVC), polystyrene (PS) and vinyl aromatic copolymers, such as vinyl aromatic-diene copolymers (such as styrene-butadiene copolymers (SBC)), vinyl aromatic-acrylonitrile copolymers (such as styrene-acrylonitrile copolymers (SAN) and α-methylstyrene-acrylonitrile copolymers (AMSAN)), vinyl aromatic-diene-acrylonitrile copolymers (such as poly(acrylonitrile-butadiene-styrene) (ABS)) or vinyl aromatic-acrylate copolymers (such as poly(acrylonitrile-styrene-acrylate) (ASA)).

[0194] Preferably, the method employs at least one post-consumer recycled vinyl aromatic copolymer B and at least one post-consumer recycled polymer A that are different from each other. More preferably, the method employs at least two different post-consumer recycled polymers A. The post-consumer recycled polymer A preferably comprises at least one polymer selected from the group consisting of polycarbonate (PC), thermoplastic polyurethane (TPU), polyalkyl (meth) acrylate, especially polymethyl methacrylate (PMMA)), polyvinyl chloride (PVC), polystyrene (PS) and vinyl aromatic copolymers, such as vinyl aromatic-diene copolymers such as styrene-butadiene copolymers (SBC), vinyl aromatic-acrylonitrile copolymers such as styrene-acrylonitrile copolymers (SAN) and α-methylstyrene-acrylonitrile copolymers (AMSAN)), vinyl aromatic-diene-acrylonitrile copolymers such as poly(acrylonitrile-butadiene-styrene) (ABS) or vinyl aromatic-acrylate copolymers such as poly(acrylonitrile-styrene-acrylate) (ASA).

[0195] The post-consumer recycled vinyl aromatic copolymer B is preferably selected from styrene-acrylonitrile copolymers, mixtures of at least one styrene-acrylonitrile copolymer with poly(acrylonitrile-butadiene-styrene) (ABS) or poly(acrylonitrile-styrene-acrylate) (ASA), and mixtures thereof.

[0196] Another aspect of the present invention is a process for preparing a polymer composition P according to the invention by melt mixing components A, B and (if present) components C and / or D. Preferably, the melt mixing of components A, B and (if present) components C and / or D is carried out in an extruder, preferably a twin-screw extruder.

[0197] Melt mixing can be carried out at a temperature range of 160°C to 260°C, preferably in an extruder. Preferably, melt mixing is carried out in an extruder at a temperature range of 180°C to 230°C. Uses and Applications

[0198] The present invention also relates to a method for preparing a polymer composition P containing at least one post-consumer recycled polymer A using a post-consumer recycled vinyl olefin copolymer B, wherein the post-consumer recycled polymer A is dissolved in the post-consumer recycled vinyl olefin copolymer B; or the post-consumer recycled polymer A is dispersed in the continuous phase of the vinyl aromatic copolymer B in the form of discontinuous phase domains, and the discontinuous phase of the post-consumer recycled polymer A at least includes domains with an average diameter in the range of >30nm to ≤5μm, preferably >30nm to ≤2μm, more preferably >30nm to ≤200nm, and usually >30nm to ≤100nm.

[0199] On the other hand, the present invention also relates to a method for recycling post-consumer polymers containing at least one polymer A, wherein the post-consumer recycled polymer A is dissolved in the post-consumer recycled vinyl olefin copolymer B; or the post-consumer recycled polymer A is dispersed in the continuous phase of the vinyl aromatic copolymer B in the form of discontinuous phase domains, and the discontinuous phase of the post-consumer recycled polymer A at least includes domains with an average diameter in the range of >30nm to ≤5μm, preferably >30nm to ≤2μm, more preferably >30nm to ≤200nm, and usually >30nm to ≤100nm.

[0200] Therefore, in other words, the present invention also relates to the use of post-consumer recycled vinyl olefin copolymer B for the preparation of a polymer composition P comprising at least one post-consumer recycled polymer A, wherein the post-consumer recycled polymer A is dissolved in the post-consumer recycled vinyl olefin copolymer B; or the post-consumer recycled polymer A is dispersed in the continuous phase of the vinyl aromatic copolymer B in the form of discontinuous phase domains, and the discontinuous phase of the post-consumer recycled polymer A at least includes domains with an average diameter in the range of >30nm to ≤5μm, preferably >30nm to ≤2μm, more preferably >30nm to ≤200nm, and typically >30nm to ≤100nm.

[0201] The present invention also relates to the use of post-consumer recycled vinyl olefin copolymer B for improving the compatibility of recycled polymer A in the polymer composition P according to the present invention, wherein the post-consumer recycled polymer A is dissolved in the post-consumer recycled vinyl olefin copolymer B; or the post-consumer recycled polymer A is dispersed in the continuous phase of the vinyl aromatic copolymer B in the form of discontinuous phase domains, and the discontinuous phase of the post-consumer recycled polymer A at least includes domains with an average diameter in the range of >30nm to ≤5μm, preferably >30nm to ≤2μm, more preferably >30nm to ≤200nm, and usually >30nm to ≤100nm.

[0202] Components A, B, C and D and the polymer composition P and preferred embodiments thereof are as described above.

[0203] The polymer composition P obtained by the process exhibits good processability and can therefore be easily processed, ie moulded by extrusion and thermoforming (eg injection moulding) into any desired shape.

[0204] A further aspect of the present invention is therefore a shaped article produced from the polymer composition P according to the invention.

[0205] The polymer composition P according to the present invention can be advantageously used in many applications, including automotive parts, such as rearview mirrors, instrument panels, front grilles, rear lights and lamp covers, door panels, center consoles, knobs and other instrument panel parts, upper and lower interior trims, seat parts, spoilers, electroplated parts, instrument panels and mounting brackets; 2-wheeler parts, such as side covers, indicator lights and indicator housings, lamps and lamp covers, fuel tank ornaments, front fenders, seat covers; computer / communication applications, such as mobile phones, smart phones, portable computers, stationary computers, GPS devices, landline phones, telefax machines, antennas and communication system parts; TV / monitor applications, such as light diffuser plates (LDP), light guide plates (LGP), front, middle and rear covers, guide stands (guide stands) and other components. necks), guide frame bases; sports / leisure applications, such as game consoles, audio and video equipment, e-book readers, intercom systems, electronic musical instruments, electric bicycles, sound system parts; office equipment applications, such as printer, copier and scanner housing parts, paper trays, feeders, separators and external parts, document holders, light pipes, transparent photo trays, printer drum units, printer platens, ink cartridges and toner cartridges; general electronics applications, such as electrical devices, plugs and switches, battery housings, payment devices, home electronics (home security and communication systems); kitchen applications, such as refrigerators, coolers, dishwashers, microwaves, etc. Microwave ovens, cookers, exhaust fans (extraction devices), coffee machines, toasters, mixers, blenders, filtered water containers; laundry applications, such as washing machines, dryers, irons; personal hygiene applications, such as electric toothbrushes, electric shavers / razors, hair dryers, shower heads, knobs and other hygienic applications, such as electroplating parts; general household, such as vacuum cleaners, carpet cleaning machines, air conditioners, air purifiers, humidifiers / dehumidifiers, water purifiers; building and construction applications, such as platforms / decks, fences / railings, roofs / roof tiles, exterior siding / cladding, exterior decoration, bottom lining (soffit linings), storm doors, door panels, window profiles, solar panel supports, drainage, solarium walls, outdoor pool steps, trim, edge strips, exterior films, flooring, sanitary applications, shower trays, high-heat pipes / ducts, window frame internal structures, solar panel housings, gutters, mixed with PVC to improve heat resistance, impact strength and color retention; additional housing applications beyond exterior PVC applications, windmill / renewable energy production components, insulation panels; medical / healthcare applications, such as intravenous systems and fluid delivery components, intravenous tubing, lumens, carbon monoxide emission tubes (co-ex tubes), intravenous infusion bags, intravenous drip chambers, needles, connectors (rigid / flexible, Y-type, valves), stopcocks, roller clamps, dialyzers, blood filters and reservoirs, diabetes devices such as injection pens and packaging;Laboratory supplies, such as titration plates, culture dishes, pipettes, sample spoons, cell growth bottles, cuvettes, centrifuge tubes, caps and closures, anesthesia machines, blood analysis trays, diagnostic test kits, retinal surgery boxes, surgical instruments, handle grips, colposcopes, electrosurgical pencils, trocars, arthroscopy, endoscopes, microlaparoscopic instruments, anesthesia devices, endoscopic tubes and parts, prostheses; respiratory and drug delivery applications, such as inhalers, sleep apnea devices, insulin pens, insulin pumps, injection pens, needle-free injection devices, syringes, nebulizers and other parts; mobile and digital health applications, such as medical monitoring Components for blood pressure monitors, diagnostic systems, CT scanners, blood pressure monitors, thermometers, pulse oximeters; fitness equipment, blood glucose meters, AEDs, ultrasound equipment, wireless, remote devices, medical trays, bags, blisters, films, outer packaging, film / multilayer film applications; packaging and other applications such as food packaging, technical packaging, containers, integrated circuit packaging, cosmetic packaging, household goods packaging, household sprayer and dispenser components, foam packaging and foam trays, cosmetic jars, industrial batteries, water filter components, food boxes, point-of-purchase displays, pens, toys, building blocks and toy shells, toy figures, films. ;

[0206] Another object of the present invention is the use of the polymer composition P according to the invention and the shaped articles produced therefrom for the various applications mentioned above.

[0207] The invention is further described in the following embodiments and patent claims. DETAILED DESCRIPTION Example

[0208] In the mechanical recycling tests, a series of polymers A-(i) to A-(viii) were blended with each other and with styrene (B-(i)) and vinyl aromatic copolymers B-(ii) to B-(v):

[0209] Extrusion compounding tests were carried out with a blend having a weight ratio of 1:1 (according to Table 1) under the following conditions: Extruder: Cooperion ZSK 30 Temperature: 260℃ Speed ​​[l / min] 200-300 Production capacity 10kg / h

[0210] Compatibility testing is done by studying micro or macro phase separation on 50μm x 50μm photographs by optical microscopy using the following evaluation scheme: + (Good compatibility): Average polymer domain size 2μm or less 0 (medium compatibility): average polymer domain size 20 μm or less -(Poor compatibility / no compatibility): No visible miscibility / domain size > 20 μm

[0211] The results are shown in Table 1. Table 1: Mechanical recovery test A-(i) A-(ii) A-(iii) A-(iv) A-(v) A-(vi) A-(vii) A-(viii) A-(i) Not applicable (n / a) 0 - - - 0 - - A-(ii) 0 not applicable - - - 0 - - A-(iii) - - not applicable + + 0 0 0 A-(iv) - - + not applicable 0 - 0 0 A-(v) - - + 0 not applicable 0 0 0 A-(vi) 0 0 0 - 0 not applicable 0 0 A-(vii) - - 0 0 0 0 not applicable 0 A-(viii) - - 0 0 0 0 0 not applicable B-(i)* - - + + - + - - B-(ii) - - + + + 0 - + B-(iii) - - + + + 0 - + B-(iv) - - + + + 0 - + B-(v) - - + + 0 - 0 0 *Reference Example

[0212] It can be seen from the data shown in Table 1 that the polymer composition P containing vinyl aromatic copolymers B-(ii) to B-(v) exhibits good or moderate compatibility with various different polymers such as polymers (A-iii) to (A-vi) and (A-viii), especially (A-iii), (A-iv), (Av) and (A-viii).

Claims

1. A polymer composition P, comprising: A: 0.1-50 parts by weight of at least one post-consumer recycled polymer as component A; B: 50-99.9 parts by weight of at least one post-consumer recycled vinyl aromatic copolymer as component B, comprising: B1: 10% to 100% by weight of at least one thermoplastic vinyl aromatic copolymer B1, comprising: B1.1: 1% to 81% by weight of repeating units of styrene and / or styrene derivatives; B1.2: 19% to 35% by weight of repeating units of acrylonitrile and / or methacrylonitrile; B1.3: 0% to 80% by weight of repeating units of at least one monomer selected from methyl methacrylate (MMA), maleic anhydride (MA) and N-phenylmaleimide (N-PMI); B1.4: 0% to 20% by weight of repeating units of at least one other comonomer different from B1.1, B1.2 and B1.3; in, B1.1, B1.2, B1.3 and B1.4 together account for 100% by weight of the thermoplastic vinyl aromatic copolymer B1; and B2: 0% to 90% by weight of at least one impact-modified polymer B2; Wherein B1 and B2 together account for 100% by weight of the vinyl aromatic copolymer B; C: 0-200 parts by weight of non-post-consumer recycled (virgin) vinyl aromatic copolymer as component C, comprising: C1: 10% to 100% by weight of at least one thermoplastic vinyl aromatic copolymer C1, comprising: C1.1: 1% to 81% by weight of repeating units of styrene and / or styrene derivatives; C1.2: 19% to 35% by weight of repeating units of acrylonitrile and / or methacrylonitrile; C1.3: 0% to 80% by weight of at least one repeating unit of a monomer selected from methyl methacrylate (MMA), maleic anhydride (MA) and N-phenylmaleimide (N-PMI); C1.4: 0% to 20% by weight of at least one repeating unit of other comonomers different from C1.1, C1.2 and C1.3; wherein C1.1, C1.2, C1.3 and C1.4 together account for 100% by weight of the thermoplastic vinyl aromatic copolymer C1; and C2: 0% to 90% by weight of at least one impact-modified polymer C2; wherein C1 and C2 together represent 100% by weight of the non-post-consumer recycled (virgin) vinyl aromatic copolymer C; and D: 0-10 parts by weight of at least one other additive as component D; wherein components A, B, C and D together account for 100% by weight of the polymer composition P; and wherein the post-consumer recycled polymer A is dissolved in the vinyl aromatic copolymer B and optionally the vinyl aromatic copolymer C, and / or wherein the post-consumer recycled polymer A is dispersed in the continuous phase of the vinyl aromatic copolymer B and the optional vinyl aromatic copolymer C in the form of discontinuous phase domains, and The discontinuous phase of post-consumer recycled polymer A comprises at least domains with an average diameter ranging from >30 nm to ≤5 μm, preferably >30 nm to ≤2 μm, more preferably >30 nm to ≤200 nm, and typically >30 nm to ≤100 nm.

2. The polymer composition P according to claim 1, characterized in that The post-consumer recycled polymer A is dispersed in the continuous phase of the vinyl aromatic copolymer B and the optional vinyl aromatic copolymer C in the form of discontinuous phase domains, and the discontinuous phase of the post-consumer recycled polymer A comprises: (i) domains with an average diameter in the range of >30 nm to ≤5 μm, preferably >30 nm to ≤2 μm, more preferably >30 nm to ≤200 nm, typically >30 nm to ≤100 nm, and (ii) optionally phase domains having an average diameter in the range of >0.1 nm to ≤30 nm.

3. The polymer composition P according to any one of claims 1 to 3, characterized in that The post-consumer recycled polymer A comprises at least one polymer selected from the group consisting of polycarbonate (PC), thermoplastic polyurethane (TPU), polyamide (PA), polyalkyl (meth)acrylate, especially polymethyl methacrylate (PMMA), polyvinyl chloride (PVC), polystyrene (PS) and vinyl aromatic copolymers, such as vinyl aromatic-diene copolymers (such as styrene-butadiene copolymers (SBC)), vinyl aromatic-acrylonitrile copolymers (such as styrene-acrylonitrile copolymers (SAN) and α-methylstyrene-acrylonitrile copolymers (AMSAN)), vinyl aromatic-diene-acrylonitrile copolymers (such as poly(acrylonitrile-butadiene-styrene) (ABS)) or vinyl aromatic-acrylate copolymers (such as poly(acrylonitrile-styrene-acrylate) (ASA)).

4. The polymer composition P according to any one of claims 1 to 3, characterized in that The post-consumer recycled polymer A comprises at least one polymer selected from thermoplastic polyurethane (TPU), polymethyl methacrylate (PMMA), polyamide (PA), polycarbonate (PC), α-methylstyrene-acrylonitrile copolymer (AMSAN) and polystyrene (PS).

5. The polymer composition P according to any one of claims 1 to 4, characterized in that The post-consumer recycled vinyl aromatic copolymer component B is selected from styrene-acrylonitrile copolymers, blends of at least one styrene-acrylonitrile copolymer and a mixture of poly(acrylonitrile-butadiene-styrene) (ABS) or poly(acrylonitrile-styrene-acrylate) (ASA), and mixtures thereof.

6. The polymer composition P according to any one of claims 1 to 5, characterized in that The post-consumer recycled polymer A and the post-consumer recycled vinyl aromatic polymer B are selected from different polymer classes.

7. The polymer composition P according to any one of claims 1 to 4, characterized in that The polymer composition comprises: (a) at least one PMMA as component A and at least one SAN as component B; (b) at least one PMMA as component A and at least one ABS as component B; (c) at least one PMMA as component A and at least one ASA as component B; (d) at least one TPU as component A and at least one SAN as component B; (e) at least one TPU as component A and at least one ABS as component B; (f) at least one TPU as component A and at least one ASA as component B; (g) at least one AMSAN as component A and at least one SAN as component B; (h) at least one AMSAN as component A and at least one ABS as component B; (i) at least one AMSAN as component A and at least one ASA as component B; (j) at least one PC as component A and at least one SAN as component B; (k) at least one PC as component A and at least one ABS as component B; (1) at least one PC as component A and at least one ASA as component B; (m) at least one PA as component A and at least one SAN as component B; (n) at least one PA as component A and at least one ABS as component B; (o) at least one PA as component A and at least one ASA as component B; or a combination of the above.

8. A method for mechanically recovering post-consumer recycled polymer A, characterized in that: The method comprises the following method steps: (i) providing at least one post-consumer recycled polymer A; (ii) providing at least one vinyl aromatic copolymer B; (iii) optionally providing at least one non-post-consumer recycled vinyl aromatic copolymer C; (iv) optionally providing other additives D; (v) melt mixing 0.1-50 parts by weight of said at least one post-consumer recycled polymer A, 50-99.9 parts by weight of said at least one post-consumer recycled vinyl aromatic copolymer B and optionally 0-200 parts by weight of a substantially non-post-consumer recycled vinyl aromatic copolymer C, and optionally 0-10 parts by weight of at least one other additive component D; (vi) extruding the molten mixture obtained in process step (v); The post-consumer recycled polymer A comprises at least one polymer selected from polyolefins, polyamides, polyesters, polycarbonates (PC), thermoplastic polyurethanes (TPU), polyalkyl (meth)acrylates, polyvinyl chloride (PVC), polystyrene (PS) and vinyl aromatic copolymers.

9. The method according to claim 8, characterized in that The at least one post-consumer recycled vinyl aromatic copolymer (B) is different from the at least one post-consumer recycled polymer (A).

10. The method according to claim 8 or 9, characterized in that: The post-consumer recycled polymer A and the post-consumer recycled vinyl aromatic polymer B are selected from different polymer classes.

11. The method according to any one of claims 8 to 10, characterized in that: The post-consumer recycled polymer A comprises at least one polymer selected from thermoplastic polyurethane (TPU), polymethyl methacrylate (PMMA), polyamide (PA), polycarbonate (PC), α-methylstyrene-acrylonitrile copolymer (AMSAN) and polystyrene (PS).

12. The method according to any one of claims 8 to 11, characterized in that: The post-consumer recycled vinyl aromatic copolymer component B is selected from styrene-acrylonitrile copolymers, blends of at least one styrene-acrylonitrile copolymer and a mixture of poly(acrylonitrile-butadiene-styrene) (ABS) or poly(acrylonitrile-styrene-acrylate) (ASA), and mixtures thereof.

13. Use of a post-consumer recycled vinyl aromatic copolymer B for preparing a polymer composition P comprising at least one post-consumer recycled polymer A, characterized in that The post-consumer recycled polymer A is dissolved in the post-consumer recycled vinyl olefin copolymer B; or the post-consumer recycled polymer A is dispersed in the continuous phase of the vinyl aromatic copolymer B in the form of discontinuous phase domains, and the discontinuous phase of the post-consumer recycled polymer A at least includes domains with an average diameter in the range of >30nm to ≤5μm, preferably >30nm to ≤2μm, more preferably >30nm to ≤200nm, and usually >30nm to ≤100nm.

14. The use according to claim 13, characterized in that The post-consumer recycled polymer A and the post-consumer recycled vinyl aromatic polymer B are selected from different polymer classes.

15. The use according to claim 13 or 14, characterized in that The polymer composition P comprises: (a) at least one PMMA as component A and at least one SAN as component B; (b) at least one PMMA as component A and at least one ABS as component B; (c) at least one PMMA as component A and at least one ASA as component B; (d) at least one TPU as component A and at least one SAN as component B; (e) at least one TPU as component A and at least one ABS as component B; (f) at least one TPU as component A and at least one ASA as component B; (g) at least one AMSAN as component A and at least one SAN as component B; (h) at least one AMSAN as component A and at least one ABS as component B; (i) at least one AMSAN as component A and at least one ASA as component B; (j) at least one PC as component A and at least one SAN as component B; (k) at least one PC as component A and at least one ABS as component B; (1) at least one PC as component A and at least one ASA as component B; (m) at least one PA as component A and at least one SAN as component B; (n) at least one PA as component A and at least one ABS as component B; (o) at least one PA as component A and at least one ASA as component B; or a combination of the above.

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