Blended polypropylene composition

Abstract

The present invention relates to blended polypropylene compositions, methods of making blended polypropylene compositions and compositions obtainable thereby. The invention also relates to the use of a recycled composition obtained by processing a waste plastic material derived from post-consumer and / or post-industrial waste for improving the impact strength and gloss of blended polypropylene compositions.

Description

[0001] The present invention relates to a blended polypropylene composition, a method for manufacturing a blended polypropylene composition, and a composition obtainable thereby.

[0002] Compositions comprising a multiphase propylene copolymer and an inorganic filler are widely used in applications requiring good mechanical properties such as impact strength. Certain applications require not only mechanical properties but also gloss properties, and more preferably scratch resistance.

[0003] Methods for recycling polypropylene are known in the art, such as WO2012117250, US9670344, and WO2014040634. However, recycled polypropylene generally suffers from a deterioration in properties compared to virgin polypropylene. A typical solution to this problem is to dilute recycled polypropylene in virgin polypropylene to obtain a polypropylene blend, but polypropylene blends also generally suffer from the deterioration of recycled polypropylene.

[0004] It is an object of the present invention to provide a blended propylene composition having improved impact strength and gloss. Another object of the present invention is to provide a blended propylene composition having improved impact strength, gloss, and scratch resistance.

[0005] In one aspect of the present invention, there is provided a blended propylene composition comprising:

[0006] (A) 5 to 50% by weight of a recycled polypropylene composition having a melt flow index of 10 to 50 dg / min measured at 230 °C with a 2.16 kg load according to ISO1133-1:2011,

[0007] (B) 30 to 70% by weight of at least one multiphase propylene copolymer having a melt flow index of 10 to 90 dg / min measured at 230 °C with a 2.16 kg load according to ISO1133-1:2011,

[0008] (C) 5 to 30% by weight of an inorganic filler, and

[0009] (D) 5 to 30% by weight of at least one polyolefin-based elastomer.

[0010] Compared to a baseline composition obtained by replacing the recycled polypropylene composition in the blended propylene composition with the same amount of at least one multiphase propylene copolymer,

[0011] ● the Izod notched impact strength of the blended propylene composition measured at 23 °C by ISO180 / 1A(II) is increased by at least 10%; and / or

[0012] ● the gloss of the blended propylene composition measured at 20 degrees by ISO 2813 is increased by at least 10%.

[0013] In some cases, the scratch resistance of the blend composition measured on an Erichsen scratching device with a load of 10 N according to the Volkswagen AG PV 3952 (2002) scratching method is reduced by at least 5%.

[0014] In another aspect of the present invention, there is provided a method for manufacturing a blend composition, which comprises the following steps:

[0015] i) Processing waste plastic materials derived from post-consumer and / or post-industrial waste to obtain (A) a recycled composition,

[0016] ii) Melting and mixing the recycled composition with (B) at least one multiphase propylene copolymer, (C) an inorganic filler, and (D) at least one polyolefin-based elastomer.

[0017] In some cases, the Izod notched impact strength of the blend composition is increased by 10 to 50%, preferably 15 to 45%, more preferably 17% to 41%.

[0018] In some cases, the gloss of the blend composition is increased by 10 to 200%, preferably 15 to 190%, more preferably 19 to 180%.

[0019] In some cases, the scratch resistance of the blend composition is reduced by 5 to 90%, preferably 7 to 80%, more preferably 8 to 70%.

[0020] In some cases, the Izod notched impact strength of the blend composition is 37 to 60 kJ / m 2 preferably 39 to 50 kJ / m 2 .

[0021] In some cases, the gloss of the blend composition is 7.0 to 30, preferably 8 to 20.

[0022] In some cases, the scratch resistance of the blend composition is 1.0 to 6.2, preferably 1.9 to 6.0.

[0023] It has been unexpectedly found that mixing a specific type of recycled composition with a composition containing a filled inorganic filler comprising a specific type of multiphase propylene copolymer according to the present invention results in an improvement in impact strength, gloss, and / or scratch resistance at low cost.

[0024] Method for manufacturing a blend composition

[0025] The method according to the present invention comprises the following steps:

[0026] i) Processing waste plastic materials derived from post-consumer and / or post-industrial waste to obtain (A) a recycled polypropylene composition,

[0027] ii) melt-mixing the recycled polypropylene composition with (B) at least one multiphase propylene copolymer, (C) an inorganic filler, and (D) at least one polyolefin-based elastomer.

[0028] In step i), post-consumer and / or post-industrial waste is processed by known methods including, for example, washing, sorting, and / or grinding to obtain a recycled composition. The recycled composition obtained by step i) may be in the form of pellets.

[0029] In step ii), the recycled composition thus obtained, the multiphase propylene copolymer, the inorganic filler, the polyolefin-based elastomer, and optionally additional additives are melt-mixed using any suitable means to obtain the blend composition according to the present invention.

[0030] Preferably, the blend composition of the present invention is made in a form that allows for easy processing into shaped articles in subsequent steps, such as in pellet or granule form.

[0031] Preferably, the blend composition of the present invention is in pellet or granule form, such as obtained by mixing all components in an apparatus like an extruder; the advantage is that the composition has a uniform and well-defined additive concentration.

[0032] (A) Recycled composition

[0033] The recycled composition used in the present invention is obtained by processing waste plastic materials derived from post-consumer and / or post-industrial waste, preferably post-industrial waste, by known methods including, for example, washing, sorting, and / or grinding.

[0034] The recycled composition contains at least 90% by weight, preferably at least 92% by weight, more preferably at least 95% by weight, even more preferably at least 98% by weight, based on the recycled composition, of an propylene-based polymer. Herein, the propylene-based polymer is understood to be a propylene homopolymer, including random copolymers and (multi)block copolymers or multiphase propylene copolymers, and propylene copolymers having at least 50% by weight, for example at least 80% by weight, of propylene monomer units.

[0035] The waste plastic materials may contain an amount of propylene-based polymer that is substantially the same as that of the recycled composition. The waste plastic materials may contain at least 90% by weight, based on the waste plastic materials, of an propylene-based polymer.

[0036] The recycled composition has an ash content of less than 10% by weight, preferably at most 8% by weight, at most 6% by weight, at most 5% by weight, at most 3% by weight or at most 1% by weight, based on the recycled composition, as determined by ISO 3451. The low ash content can result in better aesthetic qualities and allow for better control of the amount of inorganic materials in the blend compositions of the present invention.

[0037] The recycled composition has a melt flow index of 10 to 100 dg / min, preferably 10 to 50 dg / min, more preferably 15 to 30 dg / min, more preferably 18 to 22 dg / min, such as 20 dg / min, as determined by ISO 1133-1:2011 at 230 °C with a 2.16 kg load.

[0038] Preferably, the ratio of the melt flow index of the recycled composition to the melt flow index of the propylene-based matrix of the multiphase propylene polymer is from 0.1 to 5.0, preferably from 0.2 to 2.0, such as from 0.25 to 1.5. Both melt flow indices are determined by ISO 1133-1:2011 at 230 °C with a 2.16 kg load.

[0039] The recycled composition has a Izod notched impact strength of 2.0 to 7.0 kJ / m 2 、for example 4.0 to 5.0 kJ / m 2 as determined by ISO 180 / 1A(II) at 23 °C.

[0040] The recycled composition has a flexural modulus of 1000 to 1500 MPa, such as 1300 to 1400 MPa, as determined by ISO 178 (parallel) at 23 °C.

[0041] This results in the blend compositions according to the present invention having good mechanical properties.

[0042] Preferably, the amount of the recycled composition relative to the blend composition according to the present invention is from 5 to 50% by weight, preferably from 7 to 35% by weight, more preferably from 10 to 30% by weight, and even more preferably from 15 to 25% by weight.

[0043] Preferably, the weight ratio of the recycled composition to the multiphase propylene copolymer is from 1:10 to 1:1, preferably from 1:5 to 4:5, more preferably from 1:5 to 3:5.

[0044] (B) Multiphase propylene copolymer

[0045] The blend composition according to the present invention comprises at least one multiphase propylene copolymer. Preferably, the amount of the multiphase propylene copolymer relative to the blend composition according to the present invention is 30 to 70% by weight, preferably 35 to 65% by weight, more preferably 40 to 60% by weight, such as 45% by weight, 50% by weight or 55% by weight.

[0046] For the purposes of the present invention, unless otherwise specified, the amount of the multiphase propylene copolymer means the total amount of at least one multiphase propylene copolymer.

[0047] The multiphase propylene copolymer consists of (a1) a propylene-based matrix and (a2) a dispersed ethylene-α-olefin copolymer; wherein the propylene-based matrix consists of a propylene homopolymer and / or a propylene copolymer, and the propylene copolymer consists of at least 90% by weight of propylene monomer units and at most 10% by weight of ethylene and / or α-olefin monomer units based on the total weight of the propylene-based matrix; wherein the sum of the total amount of the propylene-based matrix and the total amount of the dispersed ethylene-α-olefin copolymer in the multiphase propylene copolymer is 100% by weight.

[0048] Multiphase propylene copolymers are also known as impact propylene copolymers or propylene block copolymers and are an important class of polymers due to their attractive combination of mechanical properties such as impact strength over a wide temperature range and their low cost. These copolymers are widely used, ranging from the consumer industry (e.g., packaging and household goods), the automotive industry to electrical applications.

[0049] Multiphase propylene copolymers are generally prepared in one or more reactors by polymerizing propylene in the presence of a catalyst and subsequently polymerizing an ethylene-α-olefin mixture. The resulting polymeric material is multiphase, but the specific morphology generally depends on the preparation method used and the monomer ratios.

[0050] The multiphase propylene copolymer used in the present invention can be produced using any conventional technique known to those skilled in the art, such as multistage process polymerization, such as bulk polymerization, gas phase polymerization, slurry polymerization, solution polymerization or any combination thereof. Any conventional catalyst system can be used, such as Ziegler-Natta or metallocene. Such techniques and catalysts are described, for example, in WO06 / 010414; Polypropylene and other Polyolefins, Ser van der Ven, Studies in Polymer Science 7, Elsevier 1990; WO06 / 010414, US4399054 and US4472524.

[0051] Preferably, the multiphase propylene copolymer is prepared using a Ziegler-Natta catalyst.

[0052] A multiphase propylene copolymer can be prepared by a process comprising the following:

[0053] - polymerizing propylene and optionally ethylene and / or an α-olefin in the presence of a catalyst system to obtain a propylene-based matrix, and

[0054] - subsequently polymerizing ethylene and an α-olefin in the propylene-based matrix in the presence of a catalyst system to obtain a dispersed ethylene-α-olefin copolymer. These steps are preferably carried out in different reactors. The catalyst systems for the first and second steps can be different or the same.

[0055] The multiphase propylene copolymer of the composition of the present invention consists of a propylene-based matrix and a dispersed ethylene-α-olefin copolymer. The propylene-based matrix generally forms the continuous phase in the multiphase propylene copolymer. As is well known in the art, the amounts of the propylene-based matrix and the dispersed ethylene-α-olefin copolymer can be determined by 13 C-NMR.

[0056] The propylene-based matrix consists of a propylene homopolymer and / or a propylene copolymer, the propylene copolymer consisting of at least 90% by weight of propylene monomer units and at most 10% by weight of comonomer units selected from ethylene monomer units and α-olefin monomer units having 4 to 10 carbon atoms, for example consisting of at least 95% by weight of propylene monomer units and at most 5% by weight of comonomer units.

[0057] Preferably, the comonomer in the propylene copolymer of the propylene-based matrix is selected from ethylene, 1-butene, 1-pentene, 4-methyl-1-pentene, 1-hexene, 1-heptene and 1-octene, and is preferably ethylene.

[0058] Preferably, the propylene-based matrix consists of a propylene homopolymer. The fact that the propylene-based matrix consists of a propylene homopolymer is advantageous because higher rigidity is obtained compared to the case where the propylene-based matrix is a propylene-α-olefin copolymer.

[0059] Preferably, the propylene-based matrix is present in an amount of 70 to 90% by weight, preferably 74 to 86% by weight, based on the total multiphase propylene copolymer.

[0060] The propylene-based matrix is preferably semi-crystalline, i.e., it is not 100% amorphous nor 100% crystalline. For example, the propylene-based matrix is at least 40% crystalline, such as at least 50%, such as at least 60% crystalline and / or such as at most 80%, such as at most 70% crystalline. For example, the propylene-based matrix has a crystallinity of 60% to 70%. For the purposes of the present invention, the crystallinity of the propylene-based matrix is measured according to ISO11357-1 and ISO11357-3 of 1997, using differential scanning calorimetry (DSC), using a scanning rate of 10 °C / min, a sample of 5 mg, and the second heating curve using 207.1 J / g as the theoretical standard for 100% crystalline material.

[0061] In addition to the propylene-based matrix, the multiphase propylene copolymer further comprises a dispersed ethylene-α-olefin copolymer. The dispersed ethylene-α-olefin copolymer is also referred to herein as the 'dispersed phase'. The dispersed phase is embedded in the multiphase propylene copolymer in a discontinuous form. The particle size of the dispersed phase is generally 0.05 to 2.0 microns, as determined by transmission electron microscopy (TEM). The amount of the dispersed ethylene-α-olefin copolymer in the multiphase propylene copolymer may sometimes be referred to herein as RC.

[0062] Preferably, the amount of ethylene monomer units in the ethylene-α-olefin copolymer is 34 to 58% by weight, preferably 44 to 48% by weight. The amount of ethylene monomer units in the dispersed ethylene-α-olefin copolymer in the multiphase propylene copolymer may sometimes be referred to herein as RCC2.

[0063] The α-olefin in the ethylene-α-olefin copolymer is preferably selected from α-olefins having 3 to 8 carbon atoms. Examples of suitable α-olefins having 3 to 8 carbon atoms include, but are not limited to, propylene, 1-butene, 1-pentene, 4-methyl-1-pentene, 1-hexene, 1-heptene, and 1-octene. More preferably, the α-olefin in the ethylene-α-olefin copolymer is selected from α-olefins having 3 to 4 carbon atoms and any mixtures thereof, and more preferably the α-olefin is propylene, in which case the ethylene-α-olefin copolymer is an ethylene-propylene copolymer.

[0064] (Before mixing the multiphase propylene copolymer into the composition of the present invention) The MFI (MFI rubber) of the dispersed ethylene α-olefin copolymer may be, for example, at least 0.001 dg / min, at least 0.03 dg / min or at least 0.05 dg / min, and / or for example at most 0.1 dg / min or 0.01 dg / min. The MFI rubber is calculated according to the following formula:

[0065]

[0066] Wherein, MFI of the multiphase is the MFI (dg / min) of the multiphase propylene copolymer measured according to ISO1133-1:2011 (2.16 kg / 230 °C), MFI of the matrix is the MFI (dg / min) of the propylene-based matrix measured according to ISO1133-1:2011 (2.16 kg / 230 °C), matrix content is the fraction of the propylene-based matrix in the multiphase propylene copolymer, and rubber content is the fraction of the dispersed ethylene-α-olefin copolymer in the multiphase propylene copolymer. The sum of the matrix content and the rubber content is 1. For the avoidance of any doubt, Log in the formula means log10.

[0067] Preferably, the dispersed ethylene-α-olefin copolymer is present in an amount of 10 to 30% by weight, preferably 14 to 26% by weight, based on the total multiphase propylene copolymer.

[0068] In the multiphase propylene copolymer of the composition of the present invention, the sum of the total weight of the propylene-based matrix and the total weight of the dispersed ethylene-α-olefin copolymer is 100% by weight of the multiphase propylene copolymer.

[0069] The multiphase propylene copolymer can be divided into a xylene-soluble part (CXS) and a xylene-insoluble part (CXI). Preferably, the xylene-soluble part of the multiphase propylene copolymer is 12.9 to 27.8% by weight, preferably 13 to 22% by weight, based on the total amount of the multiphase propylene copolymer as measured according to ISO16152:2005.

[0070] Preferably, in the multiphase propylene copolymer according to the present invention, the comonomer in the propylene-α-olefin copolymer is selected from the group consisting of ethylene and α-olefins having 4 to 10 carbon atoms, and the α-olefin in the ethylene-α-olefin copolymer is selected from α-olefins having 3 to 8 carbon atoms. Most preferably, in the multiphase propylene copolymer according to the present invention, the comonomer in the propylene-α-olefin copolymer is ethylene and the α-olefin in the ethylene-α-olefin copolymer is propylene.

[0071] The values of MFI of the propylene-based matrix (MFI matrix) and MFI of the dispersed ethylene-α-olefin elastomer (MFI rubber) mentioned herein are understood to be the values before mixing the multiphase propylene copolymer with other components to obtain the composition according to the present invention.

[0072] The value of MFI of the multiphase propylene copolymer (MFI multiphase) refers to the original MFI value of the multiphase propylene copolymer before subjecting it to visbreaking or converting it by melt mixing with peroxide.

[0073] The multiphase propylene copolymer is preferably a reactor-grade multiphase propylene copolymer.

[0074] Preferably, the xylene-soluble fraction of the multiphase propylene copolymer has an intrinsic viscosity IV of 3.5 to 6.0 dl / g, preferably 3.8 to 5.5 dl / g, measured in decalin at 135 °C according to ISO 1628-1:2009 CXS .

[0075] Preferably, the xylene-insoluble fraction of the multiphase propylene copolymer has an intrinsic viscosity IV of 1.28 to 1.50, preferably 1.3 to 1.4 dl / g, measured in decalin at 135 °C according to ISO 1628-3:2010 CXI .

[0076] Preferably, IV CXS / IV CXI is 2 to 5, preferably 2.5 to 4.5, where:

[0077] IV CXS is the intrinsic viscosity of the xylene-soluble fraction of the multiphase propylene copolymer, and IV CXI is the intrinsic viscosity of the xylene-insoluble fraction of the multiphase propylene copolymer.

[0078] The multiphase propylene copolymer in the composition according to the invention has a melt flow index of 10 to 90 dg / min, preferably 12 to 86 dg / min, measured according to ISO 1133-1:2011 (2.16 kg / 230 °C), such as at most 84 dg / min, at most 82 dg / min, at most 80 dg / min or at most 79 dg / min.

[0079] In some cases, the blend composition of the invention comprises two or more multiphase propylene copolymers having different comonomers and / or MFI.

[0080] (C) Inorganic filler

[0081] The blend composition according to the invention further comprises an inorganic filler.

[0082] Suitable examples of inorganic fillers include, but are not limited to, talc, calcium carbonate, wollastonite, barium sulfate, kaolin, glass flakes, glass fibers, layered silicates (bentonite, montmorillonite, saponite) and mica, and mixtures thereof.

[0083] For example, the inorganic filler is selected from talc, calcium carbonate, wollastonite, mica and mixtures thereof. More preferably, the inorganic filler is talc.

[0084] Sedimentation analysis according to Stokes' law (ISO 13317-3:2001), the median particle size (D50) of talc is preferably 0.1 to 10.2 μm, preferably 0.3 to 8.1 μm, more preferably 0.5 to 5.2 μm, even more preferably 0.6 to 2.5 μm.

[0085] Preferably, the amount of the inorganic filler relative to the blend composition is 5.0 to 30% by weight, preferably 10 to 25% by weight, more preferably 15 to 23% by weight.

[0086] (D) Polyolefin-based elastomer

[0087] The blend composition according to the present invention further comprises at least one polyolefin-based elastomer.

[0088] The polyolefin-based elastomer is preferably selected from the group consisting of ethylene-1-butene copolymer, ethylene-1-hexene copolymer, ethylene-1-octene copolymer, and mixtures thereof, more preferably the elastomer is selected from ethylene-1-octene copolymer or ethylene-1-octene copolymer or mixtures thereof.

[0089] Preferably, the density of the polyolefin-based elastomer is 0.845 to 0.883 g / cm as measured according to ASTM D792-13 3 , preferably 0.853 to 0.875 g / cm 3 , more preferably 0.860 to 0.870 g / cm 3 .

[0090] Preferably, the MFI of the polyolefin-based elastomer is 0.3 to 18.0, preferably 0.5 to 14.2 dg / min as measured according to ASTM D1238-13, 190 °C, 2.16 kg.

[0091] The Shore A hardness of the polyolefin-based elastomer is preferably 35 to 90, preferably 42 to 69, more preferably 47 to 60 as measured according to ASTM D2240-15, 1 s.

[0092] The polyolefin-based elastomer suitable for use in the present invention is commercially available, for example, it can be purchased from Exxon Chemical Company in Houston, Texas under the trademark EXACT TM , or it can be purchased from Dow Chemical Company in Midland, Michigan under the trademark ENGAGE TM polymer (a series of metallocene-catalyzed elastomers), or it can be purchased from the MITSUI Chemicals group in Minato, Tokyo under the trademark TAFMER TM , or it can be purchased from SABIC under the trademarks Fortify TM and CohereTM purchased.

[0093] The polyolefin-based elastomers can be prepared using methods known in the art, for example, by using single-site catalysts, i.e., catalysts in which the transition metal component is an organometallic compound and in which at least one ligand has a cyclopentadienyl anion structure, and this ligand is bonded and coordinated to the transition metal cation through the anion structure. This type of catalyst is also known as a "metallocene" catalyst. Metallocene catalysts are described, for example, in U.S. Patent Nos. 5,017,714 and 5,324,820. The elastomers can also be prepared using conventional types of multiphase multi-site Ziegler-Natta catalysts.

[0094] Preferably, the amount of ethylene incorporated into the polyolefin-based elastomer is at least 45 wt%. More preferably, the amount of ethylene incorporated into the polyolefin-based elastomer is at least 48 wt%, such as at least 50 wt%. The amount of ethylene incorporated into the polyolefin-based elastomer can generally be up to 95 wt%, such as up to 85 wt%, such as up to 75 wt%, such as up to 65 wt%, such as up to 60 wt%, such as up to 58 wt%.

[0095] The amount of the polyolefin-based elastomer relative to the blend composition is 5-30 wt%, preferably 10-25 wt%, more preferably 15-22 wt%.

[0096] For the purposes of the present invention, unless otherwise specified, the amount of the polyolefin-based elastomer means the total amount of at least one polyolefin-based elastomer.

[0097] In some cases, the blend compositions of the present invention comprise two or more polyolefin-based elastomers having different comonomers and / or MFIs.

[0098] Preferably, the sum of (A), (B), (C) and (D) relative to the blend composition is at least 90 wt%, at least 95 wt%, at least 98 wt%, at least 99 wt% or 100 wt%.

[0099] (E) Additive

[0100] The blend composition according to the present invention may also contain additives such as nucleating agents and clarifying agents, stabilizers, release agents, plasticizers, antioxidants, lubricants, antistatic agents, crosslinking agents, anti-scratch agents, high-performance fillers, pigments and / or colorants, flame retardants, foaming agents, acid scavengers, recycling additives, antimicrobial agents, anti-fogging additives, slip additives, anti-blocking additives, polymer processing aids and the like. Such additives are well known in the art. The amount of the additive is preferably at least 0.1% by weight and at most 5.0% by weight, preferably at most 4.5% by weight, preferably at most 4.0% by weight, more preferably at most 3.8% by weight based on the total amount of the blend composition.

[0101] Preferably, the sum of (A), (B), (C), (D) and (E) is 100% by weight relative to the blend composition.

[0102] Other aspects

[0103] The present invention also relates to an article comprising the composition according to the present invention, preferably wherein the article is an automotive part, preferably wherein the amount of the polymer composition according to the present invention is at least 95% by weight, preferably at least 98% by weight based on the total amount of the article.

[0104] Preferably, the automotive parts are selected from external and internal, visible and partially visible applications such as bumper fascia, sill plates, trim pieces, upper front fascia, hood grille, windshield deflector cavity, door panels, instrument panel trim, seat upholstery, center console, cup holder and cup arm, glove box, and under-hood applications such as headlamp housings.

[0105] The present invention also relates to the use of a recycled composition (A) obtained by processing waste plastic materials derived from post-consumer and / or post-industrial waste for improving the impact strength, gloss and / or scratch resistance of a composition comprising (B) at least one multiphase propylene copolymer, (C) an inorganic filler and (D) at least one polyolefin-based elastomer.

[0106] It should be noted that the present invention relates to the subject matter defined in the independent claims, either alone or in combination with any possible combinations of the features described herein, preferably in particular those combinations of the features presented in the claims. Thus, it will be understood that all combinations of features relating to the composition according to the present invention, all combinations of features relating to the method according to the present invention, and all combinations of features relating to the composition according to the present invention and features relating to the method according to the present invention are described herein.

[0107] It should also be noted that the terms "comprising", "including", and "containing" do not exclude the presence of other elements. However, it should also be understood that the description of a product / composition containing certain components also discloses a product / composition consisting of these components. A product / composition consisting of these components may be advantageous because it provides a simpler and more economical method for preparing the product / composition. Similarly, it should also be understood that the description of a method including certain steps also discloses a method consisting of these steps. A method consisting of these steps may be advantageous because it provides a simpler and more economical method.

[0108] When values are mentioned for the lower and upper limits of a parameter, it is also understood that the range resulting from the combination of the value of the lower limit and the value of the upper limit is disclosed.

[0109] The present invention is illustrated by the following examples, but the present invention is not limited thereto.

[0110] Materials used

[0111] IPC1 and IPC2 are multiphase propylene copolymers prepared by the Innovene TM process using a sequential two-reactor setup. Polypropylene homopolymer is produced in the first reactor and propylene-ethylene copolymer is produced in the second reactor.

[0112] There are three components present in the catalyst system during the polymerization process: the main catalyst, the external electron donor, and the cocatalyst. The main catalyst is prepared according to the description in the "Main Catalyst III" paragraph on page 36 of WO2016198344; the external electron donor for IPC2 is diisopropyldimethoxysilane (DiPDMS), and the external electron donor for IPC1 is n-propyltriethoxysilane (nPTES); the cocatalyst is triethylaluminum.

[0113] The process conditions for producing IPC1 and IPC2 are given in Table 1.

[0114] Table 1: Preparation Conditions for IPC1 and IPC2

[0115] Polymer IPC1 IPC2 R1 Te (°C) 69.5 66 R1 Pr (bar) 24 24 Al / Ti (mol / mol) 135 135 Si / Ti (mol / mol) 10 10 R1 H2 / C3 (mol / mol) 0.065 0.05 R1 fraction (wt%) 86 74 R2 Te (°C) 59 57 R2 Pr (bar) 24 24 R2 H2 / C3 (mol / mol) 0.0042 0.005 R2 C2 / C3 (mol / mol) 0.31 0.33 R2 fraction (wt%) 14 26

[0116] In Table 1, R1 refers to the first reactor, R2 refers to the second reactor, Te refers to temperature, Pr refers to pressure, Al / Ti is the molar ratio of the cocatalyst to the main catalyst, Si / Ti is the molar ratio of the external donor to the main catalyst, H2 / C3 is the molar ratio of hydrogen to propylene, C2 / C3 is the molar ratio of ethylene to propylene, and split is the amount of substance produced in R1 or R2 based on the amounts of the total polymers IPC1 and IPC2, respectively.

[0117] IPC1 is a multiphase copolymer consisting of a matrix of polypropylene homopolymer (86 wt%) and a dispersed phase of propylene-ethylene copolymer (14 wt%) with an MFI of 77 dg / min (ISO1133-1:2011, 230 °C, 2.16 kg). The matrix has an MFI of 230 dg / min (ISO1133-1:2011, 230 °C, 2.16 kg).

[0118] CXS (wt%) 14 <![CDATA[IV CXS (dl / g)]]> 5.3 <![CDATA[IV CXI (dl / g)]]> 1.3 <![CDATA[IV CXS / IV CXI > 4.1

[0119] The weight percentage of the xylene-soluble fraction (CXS) of the multiphase propylene copolymer is determined according to ISO16152:2005. The weight percentage of the xylene-insoluble fraction (CXI) of the multiphase propylene copolymer is calculated using the following equation:

[0120] CXI = 100 wt% - CXS

[0121] Both the xylene-soluble fraction and the xylene-insoluble fraction (CXS and CXI) obtained in this test are used in the intrinsic viscosity (IV) test.

[0122] The intrinsic viscosity (IV) of CXS and CXI is determined in decalin at 135 °C according to ISO1628-1:2009 and ISO1628-3:2010, respectively.

[0123] IPC2 is a multiphase copolymer consisting of a matrix of polypropylene homopolymer (74 wt%) and a dispersed phase of propylene-ethylene copolymer (26 wt%) with an MFI of 14 dg / min (ISO1133-1:2011, 230 °C, 2.16 kg). The matrix has an MFI of 85 dg / min (ISO1133-1:2011, 230 °C, 2.16 kg).

[0124] CXS (wt%) 21.5 <![CDATA[IV CXS (dl / g)]]> 4 <![CDATA[IV CXI (dl / g)]]> 1.4 <![CDATA[IV CXS / IV CXI > 2.9

[0125] Recycled i-PP1 is B420 commercially available from Morsinkhof.

[0126] Recycled i-PP2 is B450 commercially available from Morsinkhof.

[0127] Both recycled i-PP1 and recycled i-PP2 are produced from post-consumer household packaging waste and have the properties shown in Table 2.

[0128] Table 2. Properties of recycled i-PP1 and recycled iPP2

[0129]

[0130] Talc is a HAR commercially available from Imerys Talc. The median particle size (D50) of the talc in the HAR is 2 µm as measured by sedimentation analysis according to Stokes' law (ISO 13317-3:2001).

[0131] POE1 is Tafmer D605 commercially available from Mitsui Chemicals, which is an ethylene-butene copolymer with a density of 0.861 g / cm 3 (ASTM D792-13), an MFI of 0.5 g / 10 min (ASTM D1238-13, 2.16 kg, 190 °C), and a Shore A hardness of 58 (ASTM D2240-15).

[0132] POE2 is FORTIFY TM elastomer C5070T, which is an ethylene-1-octene copolymer with an MFI of 5.0 dg / min measured at 190 °C and 2.16 kg according to ASTM D1238-13 and a density of 0.868 g / cm 3 measured according to ASTM D792-13.

[0133] Additive package: The additive package contains 35 wt% stabilizers (standard additives including antioxidants, heat stabilizers, mold release agents, UV stabilizers, processing stabilizers) and 65 wt% masterbatch. The weight percentages are based on the total amount of the additive package.

[0134] The components shown in Table 3 are melt mixed and the compositions of CEx 1 and Ex 2-6 are obtained. The properties are measured and also shown in Table 3.

[0135] Table 3

[0136]

[0137] The ash content is measured according to ISO 3451.

[0138] The melt flow index (MFI) is measured according to ISO 1133-1:2011 at 230 °C with a 2.16 kg load.

[0139] The Izod notched impact strength is measured at 23 °C by ISO 180 / 1A(II).

[0140] The scratch resistance is measured on an Erichsen scratching device with a 10 N load according to the scratch method of Volkswagen AG's PV 3952 (2002). The resulting value dL is a measure of the scratch resistance, with a low dL value corresponding to high scratch resistance.

[0141] The glossiness was measured at angles of 20°, 60° and 85° according to ISO 2813 on injection molded granular specimens.

[0142] By comparing Comparative Example 1 with Examples 2-4, it can be seen that the use of recycled i-PP unexpectedly improved the gloss and scratch resistance of the composition. The improvement in the gloss of the composition was unexpectedly positively correlated with the amount of recycled i-PP used. Example 4 showed that different types of recycled i-PP produced similar properties of the composition.

[0143] Similar improvements in scratch resistance and gloss were also seen in Examples 5 and 6, in which different combinations of virgin PP were used.

Claims

1. A blended polypropylene composition, comprising: (A) 5 to 50% by weight of a recycled polypropylene composition having a melt flow index of 10 to 50 dg / min measured at 230 °C with a 2.16 kg load according to ISO 1133-1:2011, wherein the recycled polypropylene composition comprises at least 90% by weight, based on the recycled polypropylene composition, of an propylene-based polymer, (B) 30 to 70% by weight of at least one multiphase propylene copolymer having a melt flow index of 10 to 90 dg / min measured at 230 °C with a 2.16 kg load according to ISO 1133-1:2011, (C) 5 to 30% by weight of an inorganic filler, and (D) 5 to 30% by weight of at least one polyolefin-based elastomer.

2. The blended polypropylene composition according to claim 1, wherein the notched Izod impact strength of the blend composition is 37 to 60 kJ / m 2 , preferably 39 to 50 kJ / m 2 ; and / or wherein the glossiness of the blended composition is 7.0 to 30, preferably 8 to 20; and / or wherein the scratch resistance of the blended composition is 1.0 to 6.2, preferably 1.9 to 6.

0.

3. The blended polypropylene composition according to any one of the preceding claims, wherein the melt flow index (MFI) of the multiphase propylene copolymer is 12 to 80 dg / min measured at 230 °C with a 2.16 kg load according to ISO 1133-1:2011.

4. The blended polypropylene composition according to any one of the preceding claims, wherein the multiphase propylene copolymer consists of: (a1) an propylene-based matrix, wherein the propylene-based matrix consists of an propylene homopolymer and / or an propylene copolymer, and the propylene copolymer consists of at least 90% by weight of propylene monomer units and at most 10% by weight of ethylene and / or α-olefin monomer units based on the total weight of the propylene-based matrix, and (a2) a dispersed ethylene-α-olefin copolymer, wherein the sum of the total amount of the propylene-based matrix and the total amount of the dispersed ethylene-α-olefin copolymer in the multiphase propylene copolymer is 100% by weight; wherein the xylene-soluble portion of the multiphase propylene copolymer is 12.9 to 27.8% by weight, preferably 13 to 22% by weight, based on the total amount of the multiphase propylene copolymer measured according to ISO 16152:2005, wherein the intrinsic viscosity of the xylene-soluble portion of the multiphase propylene copolymer is 3.5 to 6.0 dl / g, preferably 3.8 to 5.5 dl / g, measured in decalin at 135 °C according to ISO 1628-1:2009.

5. The blended polypropylene composition according to any one of the preceding claims, wherein IV CXS / IV CXI is from 2 to 5, preferably from 2.5 to 4.5, wherein: IV CXS is the intrinsic viscosity of the xylene-soluble fraction of the multiphase propylene copolymer, and IV CXI is the intrinsic viscosity of the xylene-insoluble fraction of the multiphase propylene copolymer.

6. The blended polypropylene composition according to any one of the preceding claims, wherein the propylene-based matrix is present in an amount of 70 to 90% by weight, preferably 74 to 86% by weight, based on the total multiphase propylene copolymer, and the amount of ethylene monomer units in the ethylene-α-olefin copolymer in the multiphase propylene copolymer is 34 to 58% by weight, preferably 44 to 48% by weight.

7. The blended polypropylene composition according to any one of the preceding claims, wherein the recycled composition has an ash content of less than 10% by weight, based on the recycled composition, as determined by ISO 3451, wherein the recycled composition has a melt flow index of 15 to 30 dg / min as determined by ISO 1133-1:2011 at 230 °C with a 2.16 kg load, wherein the recycled composition has a notched Izod impact strength of 2.0 to 7.0 kJ / m as measured by ISO 180 / 1A at 23 °C 2 。 8. The blended polypropylene composition according to any one of the preceding claims, wherein, based on the total weight of the blended composition, the amount of the recycled composition is 7 to 35% by weight, more preferably 10 to 30% by weight, and even more preferably 15 to 25% by weight; the amount of the at least one multiphase propylene copolymer is 35 to 65% by weight, more preferably 40 to 60% by weight, the amount of the inorganic filler, based on the blended composition, is 10 to 25% by weight, more preferably 15 to 23% by weight, and the amount of the at least one polyolefin-based elastomer, based on the blended composition, is 10 to 25% by weight, more preferably 15 to 22% by weight.

9. A method for producing a blended composition according to any one of the preceding claims, comprising the steps of: i) processing waste plastics derived from post-consumer and / or post-industrial waste to obtain (A) a recycled polypropylene composition, ii) melt-blending the recycled polypropylene composition with (B) at least one multiphase propylene copolymer, (C) an inorganic filler, and (D) at least one polyolefin-based elastomer.

10. A blended composition prepared by the method according to claim 9.

11. A method for producing an article, comprising the method according to claim 9 and the step of injection molding the blended composition to obtain the article.

12. An article comprising the blended composition according to any one of claims 1-8 and 10 above or prepared by the method according to claim 11, preferably wherein the article is an automotive part.

13. The article according to claim 12, wherein the article is an automotive part selected from: exterior and interior, visible and partially visible applications, such as bumper fascia, sill plates, trim pieces, upper front fascia, hood grille, windshield deflector cavity, door panels, instrument panel trim, seat upholstery, center console, cup holders and cup arms, glove box, and under-hood applications, such as headlamp housings.

14. Use of (A) a recycled composition obtained by processing waste plastics derived from post-consumer and / or post-industrial waste for improving the impact strength and gloss of a composition comprising (B) at least one multiphase propylene copolymer, (C) an inorganic filler, and (D) at least one polyolefin-based elastomer.

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