Compatibilization of post-consumer resins

Abstract

A composition containing post-consumer recycled (PCR) waste is described. The PCR is combined with at least one virgin resin and a propylene-based compatibilizer that strengthens the blend between the PCR and the virgin resin and improves one or more physical properties of the composition. The propylene-based compatibilizer is a reactor-produced thermoplastic polyolefin or heterophasic copolymer having a semi-crystalline matrix and a rubber component. This allows for the selection of a compatibilizer that can tailor the composition's physical properties based on the end use, providing a stronger, more miscible blend.

Description

[Technical field]

[0001] This application was made under the Patent Cooperation Treaty and claims priority to U.S. Provisional Application No. 63 / 114,342, filed November 16, 2020, and U.S. Provisional Application No. 63 / 226,895, filed July 29, 2021, the entire contents of which are incorporated herein by reference. Federally sponsored research report Not applicable. See microfiche appendix Not applicable.

[0002] The present disclosure relates generally to post-consumer recycled polymer resins. [Background technology]

[0003] Rising living standards and urbanization are driving the demand for polymer products, especially polyolefin plastics. Polyolefins are popular in commercial plastic applications due to their outstanding performance and cost characteristics. For example, polyethylene (PE) is one of the most widely used and recognized polyolefins due to its high strength, extreme toughness, and durability. This allows it to be highly engineered for a variety of applications. Similarly, polypropylene (PP) is mechanically strong yet flexible, heat resistant, and resistant to many chemical solvents, including bases and acids. This makes it suitable for a variety of end-use industries, including packaging and labels, textiles, plastic parts, and various types of reusable containers.

[0004] The downside of the demand for polyolefin plastics is the increase in waste. Post-consumer plastic waste typically ends up in landfills, with about 12% being incinerated and about 9% being sent for recycling. In landfills, most plastics do not decompose rapidly, making them the main source of waste for overburdened landfills. Incineration is also not an ideal solution for treating plastic waste, as it leads to the formation of carbon dioxide and the emission of other greenhouse gases. Therefore, there is growing interest in developing ways to recycle plastic waste to reduce the burden on landfills while being environmentally friendly.

[0005] A drawback of recycling plastic waste is the difficulty in successfully producing commercially usable or desired products. Currently, recycling plastic waste involves cleaning and mechanical reprocessing of the material. Because post-consumer plastic waste often suffers from stress cracking or exposure to repeated heating cycles and UV light before recycling, the reprocessed material has reduced mechanical properties compared to virgin material. Recycled material can be easily used for things like plastic bags and disposable packaging, but pellets may be undesirable for many applications requiring safety, strength, and performance.

[0006] As such, there is a continuing need to develop compositions for utilizing post-consumer recycled polyolefin waste to produce commercially usable products. Summary of the Invention

[0007] The present disclosure relates to polyolefin compositions comprising post-consumer recycled (PCR) polyolefin resins. In particular, the compositions of the present disclosure combine PCR polyolefin resins, virgin polyolefin resins, and at least one propylene-based compatibilizer resin. The compatibilizer resin used in the compositions of the present disclosure is a reactor-produced thermoplastic or heterophasic copolymer (HECO), which contains A) a small amount (<10%) of ethylene or C4-C 10It has two components: B) polypropylene homopolymer and / or polypropylene copolymer with α-olefins, and C) rubber, which can be a biopolymer or terpolymer with monomers including propylene, ethylene and / or other (α-olefin comonomers). The propylene-based compatibilizer resin not only enhances the dispersion of PCR and virgin resin, but also improves impact resistance and provides the ability to adjust the impact stiffness ratio.

[0008] The present disclosure includes any one or more combinations of the following embodiments.

[0009] A composition comprising: a virgin resin having a first polyolefin; a post-consumer recycled resin having a second polyolefin; a polypropylene-based compatibilizer having a semi-crystalline matrix and a rubber component.

[0010] Any of the compositions described herein, wherein the first polyolefin and the second polyolefin are different polyolefins. Any of the compositions described herein, wherein the first polyolefin and the second polyolefin are the same polyolefin.

[0011] Any of the compositions described herein, wherein the first polyolefin or the second polyolefin is a polyolefin such as polyethylene or polypropylene. Any of the compositions described herein, wherein the first polyolefin and the second polyolefin are both polypropylene. The composition has a flexural modulus of about 155 to about 300 kPSI, about 160 to about 300 kPSI, about 170 to about 300 kPSI, about 170 to about 270 kPSI, or about 200 to about 270 kPSI, and a notched Izod impact at 73°F of about 0.4 to about 12 ft-lb / inch, or about 0.4 to about 1.5 ft-lb / inch.

[0012] In any of the compositions described herein, the virgin resin is present in an amount of about 20 to about 80 weight percent, or about 30 to about 80 weight percent.

[0013] In any of the compositions described herein, the post-consumer recycled resin is present in an amount of from about 5 to about 50 weight percent, or from about 5 to about 40 weight percent.

[0014] In any of the compositions described herein, the polypropylene-based compatibilizer is present in an amount of from about 10 to about 50 weight percent, or from about 10 to about 35 weight percent. Any of the compositions described herein, comprising, based on the total weight of (A), 25 to 75 wt. % of a propylene polymer (AI) having a melt flow rate value MFRI of 1.2 g / 10 min and 25 to 75 wt. % of a propylene polymer (AII) having a melt flow rate value MFRII of 73 g / 10 min (AII), wherein the MFRII / MFRI ratio is 60, and the propylene polymer (AI) and the propylene polymer (AII) are independently selected from a propylene homopolymer, a propylene random copolymer containing up to 3% ethylene, and up to 6% of at least one C4-C 10 (B) a semi-crystalline matrix selected from the group consisting of propylene random copolymers containing α-olefins and optionally up to 3% ethylene, the amount of (AI) and (AII) being the total weight of (AI) and (AII), the semi-crystalline matrix having a polydispersity index of 4 to 7, 70%; and (C) ethylene and at least one C3-C 10 and 30% rubber, which comprises a copolymer with an α-olefin and has an ethylene content of 36% in the rubber component, the amounts of (A) and (B) being the total weight of (A) and (B), and the composition has a viscosity value [η] of the xylene soluble fraction at room temperature of 7 to 9 dl / g.

[0015] In any of the compositions described herein, the polypropylene-based compatibilizer comprises: (A) a semi-crystalline matrix comprising about 25-50 wt. % of a crystalline propylene homopolymer having a solubility in xylene of 4% or less at room temperature, or a crystalline copolymer of propylene and ethylene or a C4-C8 α-olefin having an ethylene or α-olefin content of 0.5-3% and a solubility in xylene of 4% or less at room temperature; and (B) a rubber comprising about 50-75 wt. % of a partially amorphous copolymer of ethylene and a C4-C8 α-olefin having an α-olefin content of about 10-20%, the copolymer being about 10-40% soluble in xylene at room temperature.

[0016] In any of the compositions described herein, the polypropylene-based compatibilizer comprises a semi-crystalline matrix containing about 50-95% by weight of a crystalline propylene homopolymer having a solubility in xylene of 1-3% at room temperature, and a rubber containing about 5-50% by weight of a partially amorphous copolymer of ethylene and propylene, the ethylene content being about 20% to less than 100%, and the intrinsic viscosity of the xylene-soluble fraction of the copolymer being about 2-4 dl / g (in decane). The MFR of (A) may be about 2 to about 200 g / 10 min, about 2 to about 200 g / 10 min, about 2 to about 20 g / 10 min, or about 100 to about 200 g / 10 min.

[0017] In any of the compositions described herein, the polypropylene-based compatibilizer comprises: (A) a semi-crystalline matrix comprising AI) about 25-75 wt. % of a crystalline propylene homopolymer having a solubility in xylene at room temperature of less than 3% and a MFR in the range of 2-20 g / 10 min; and AII) about 5-40 wt. % of a crystalline propylene homopolymer having a MFR in the range of 40-140 g / 10 min; and (B) a rubber comprising about 5-50 wt. % of a partially amorphous copolymer of ethylene and propylene, the ethylene content being about 20-100%, and the intrinsic viscosity of the xylene-soluble fraction of the copolymer being about 2-4 dl / g (in decamethylphenyl) .

[0018] In any of the compositions described herein, the polypropylene-based compatibilizer comprises: (A) a semi-crystalline matrix comprising AI) about 25-75 wt. % of a crystalline propylene homopolymer having a solubility in xylene at room temperature of 2-4% and a MFR in the range of 60-160 g / 10 min; and AII) about 5-40 wt. % of a high density polyethylene having a MFR in the range of 40-140 g / 10 min; and B) a rubber comprising about 5-50 wt. % of a partially amorphous copolymer of ethylene and propylene, the ethylene content being about 20-100%, and the intrinsic viscosity of the xylene soluble fraction of the copolymer being about 2-4 dl / g (in decamethylphenyl) .

[0019] Any of the compositions described herein, wherein the polypropylene-based compatibilizer comprises a semi-crystalline matrix comprising: AI) 25-75 wt. % of a propylene homopolymer having a melt flow rate MFRI of 1.2 g / 10 min, based on the total weight of (A); AII) 25-75 wt. % of a propylene homopolymer having a melt flow rate value MFRII of 73 g / 10 min and a MFRII / MFRI ratio of 60, based on the total weight of (A); and a rubber comprising a copolymer of ethylene and butene, the copolymer being 36% ethylene.

[0020] An article formed from any of the compositions described herein.

[0021] An article formed from any of the compositions described herein, the article being a cap, a closure, a low pressure pipe, a bag, a sheet, a package or a film.

[0022] A method of forming an article includes mixing any of the compositions described herein in an extruder hopper, heating the composition, and extruding the heated composition into one or more desired shapes.

[0023] This Summary is provided to introduce a selection of concepts that are further described below in the Detailed Description. This Summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used as an aid in limiting the scope of the claimed subject matter. definition

[0024] As used herein, "post-consumer waste" refers to waste generated by the ultimate consumer of a material stream.

[0025] The term "recycle" refers to the processing of an item into a new raw material. When post-consumer waste is processed into a raw material rather than disposed of as solid waste, the raw material is called a "post-consumer recycled" material. In the compositions and methods disclosed herein, the term "post-consumer resin" refers to the post-consumer recycled material as a polymeric resin.

[0026] The terms "virgin" and "virgin resin" mean resin that has not been processed into a consumer item.

[0027] As used herein, the term "polymer" refers to a polymeric compound prepared by polymerizing monomers, whether of the same or different types. The term "polymer" includes homopolymers, copolymers (including block copolymers and random copolymers), polymers containing three or more monomers, interpolymers, and the like.

[0028] As used herein, the term "homopolymer" or "HOMO" means a polymer that is composed or substantially composed of units derived only from a single type of monomer; for example, a polyethylene homopolymer is a polymer that is composed or substantially composed of units derived only from ethylene, and a polypropylene homopolymer is a polymer that is composed or substantially composed of units derived only from propylene.

[0029] As used herein, the term "copolymer" refers to a polyolefin polymer that contains two types of α-olefin monomer units.

[0030] As used herein, the term "thermoplastic polyolefin" or "TPO" is used to refer to a polyolefin that becomes flexible or moldable above a certain temperature and solidifies upon cooling. The terms "reactor-made thermoplastic polyolefin" or "reactor-made thermoplastic polyolefin" or "rTPO" are used interchangeably to refer to thermoplastic polyolefins made in a reactor system. As used in this disclosure, rTPO contains two components: A) a semi-crystalline polypropylene-based matrix, and B) a rubber component, which may be a biopolymer or a terpolymer, and the rubber component comprises 30% or more (≧30%) of the rTPO.

[0031] As used herein, the term "heterophasic copolymer" or "HECO" refers to a blend of homopolymers and / or copolymers that contains two components: A) a semi-crystalline polypropylene-based matrix; and B) a rubber component, which may be a biopolymer or a terpolymer, where the rubber component comprises less than 30% (<30%) of the HECO.

[0032] In the rTPO and HECO of the present disclosure, the "semicrystalline polypropylene matrix" of component A may be at least one homopolymer (HOMO) polypropylene or at least one random copolymer (RACO) of propylene with ethylene or other α-olefin as comonomer. Component A may further contain semicrystalline polymers represented by Roman numerals after "A", e.g., "AI", "AII". One example of such a semicrystalline polypropylene matrix is ​​two homopolypolypropylenes with different MFR.

[0033] In both the rTPO and HECO of this disclosure, the rubber of component B may be a bipolymer (two comonomers) or terpolymer (three comonomers) dispersed in a semi-crystalline polypropylene matrix. The rubber has elastomeric properties and a partial amorphous phase.

[0034] As used herein, the term “α-olefin” or “α-olefin” refers to a compound having the general formula C H2 It means an olefin represented by =CH-R, where R is a linear or branched alkyl group containing 1 to 10 carbon atoms. The α-olefin may be selected from, for example, propylene, 1-butene, 1-pentene, 1-hexene, 1-octene, 1-dodecene, etc.

[0035] When used in the claims or specification in conjunction with the term "comprising," the use of the terms "a" or "an" means one or more than one word, unless the context dictates otherwise.

[0036] The term "about" refers to the stated value plus or minus the margin of error of measurement, or plus or minus 10%.

[0037] Use of the term "or" in the claims means "and / or," unless expressly stated to mean only alternatives or where the alternatives are mutually exclusive.

[0038] The terms "compris," "have," "include," and "containing" (and variations thereof) are open linking verbs which, when used in the claims, allow for the addition of other elements.

[0039] The phrase "consisting of" is closed and excludes all additional elements.

[0040] The phrase "consisting essentially of" excludes additional material elements, but allows for the inclusion of non-material elements that do not materially alter the essence of the invention.

[0041] The following abbreviations are used herein: [Table 1] [Brief description of the drawings]

[0042] These and other features, aspects, and advantages of the present disclosure will become better understood with reference to the following description and claims, as well as the drawings.

[0043] [Figure 1] FIG. 1 shows the results of die swell ratio versus apparent shear rate for three different polymer compositions. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0044] Test Method One or more of the following test methods are used to perform testing and analysis on the components of the compositions disclosed herein, the compositions themselves, and the resulting molded articles.

[0045] The term "Melt Flow Rate" (MFR) is a measure of the ability of a base resin melt to flow under pressure. Melt flow rates are determined by ASTM D1238L ("Standard Test Method for Determining Melt Flow Rate of Thermoplastics by Extrusion Plastometer"), measured at a temperature of 230°C, weight of 2.16 Kg, and g / 10 min. As used herein, the term "ASTM D 1238L" refers to the Standard Test Method for Determining the Melt Flow Rate of Thermoplastics by Extrusion Plastometer. In general, the test method measures the extrusion rate of a molten thermoplastic resin using an extrusion plastometer. After a pre-heating time, the resin is extruded through a die having a pre-defined length and hole size at a pre-defined temperature, load, and piston position in the barrel. The test method was approved on August 1, 2013, published in August 2013, and is incorporated herein by reference in its entirety. The melt flow range is the range of melt flow rates.

[0046] Density is measured in g / cm in accordance with ASTM D1505 ("Standard Test Method for Determining Density of Plastics by Density Gradient Method"). 3 As used herein, the term "ASTM D1505" refers to the test method published in 2018, the contents of which are incorporated herein by reference in their entirety.

[0047] According to ITM 20061 (titled "Infrared Spectrophotometric Determination of Ethylene Content in Propylene-Ethylene Semicrystalline Copolymers"), the monomer content of %C2 (ethylene) is determined by taking specific IR measurements on press plates prepared with the disclosed compositions and correlating these measurements with a previously derived calibration curve of known standard concentrations.

[0048] The xylene soluble fraction was measured in accordance with ASTM D5492 (Standard Test Method for Determination of Xylene Soluble Fraction in Propylene-Based Plastics) and is expressed as a percentage (%). As used herein, the term "ASTM D5492" refers to a test method published in 2017, the contents of which are incorporated herein by reference in their entirety.

[0049] The intrinsic viscosity of the xylene soluble fraction is measured at 135°C using decalin or tetralin according to ISO 1628-1 (title: "Plastics - Determination of the viscosity of polymers in dilute solution using a capillary viscometer").

[0050] Polydispersity Index (PI) measures the heterogeneity of a sample based on size. PI is measured at 200°C using a parallel plate rheometer RMS-800 sold by RHEOMETRICS (USA) at operating frequencies ranging from 0.1 rad / s to 100 rad / s. PI is calculated from the crossover modulus using the equation PI=10 5 / Gc, where Gc is the crossover modulus defined as G' = the value of G' (expressed in Pa), G' is the storage modulus, and G' is the loss modulus.

[0051] Flexural modulus (or "flexural modulus") and flexural strength (or "flexural strength") are measured in megapascals (MPa) and are measured using ASTM D790-03 (titled "Standard Test Method for Flexural Properties of Unreinforced and Reinforced Plastics and Electrical Insulating Materials"). As used herein, the term "ASTM D790" refers to a test method published in 2003, the entire contents of which are incorporated herein by reference.

[0052] Notched Izod impact strength measures the impact resistance of a material in ft-lb / in. The standard test method for notched Izod impact strength is ASTM D256-06, Method A (titled "Standard Test Method for Determining Izod Pendulum Impact Resistance of Plastics"). As used herein, the term "ASTM D256" refers to the test method published in 2006. Unless otherwise noted, the temperature for this test is 73°F.

[0053] Tensile strength and tensile modulus are given in megapascals (MPa), and tensile elongation (or strain) is given in %, and are measured using ASTM D638-03 (Standard Test Method for Tensile Properties of Plastics). As used herein, the term "ASTM D638" refers to the test method published in 2003, the entire contents of which are incorporated herein by reference.

[0054] Die swell measures how much the polymer extrudate expands after passing through a die opening. Die well is measured on a ROSAND RH7 capillary rheometer at 190°C with a barrel and die of L / D 16 (16mm length / 1mm diameter). The polymer is allowed to dwell at 190°C for 5 minutes and the extrusion diameter is measured at a series of shear rates from 21 1 / sec to 4500 1 / sec. The reported die swell ratio is the ratio of the cross section of the extrudate to the cross section of the die opening at a given shear rate.

[0055] For more information about the above ASTM standards, please visit the ASTM website at www.astm.org or contact ASTM Customer Service at service@astm.org.

[0056] The present disclosure provides novel compositions for utilizing post-consumer recycled (PCR) polyolefin waste. In particular, PCR polyolefin is combined with virgin material and at least one propylene-based compatibilizer, which is a thermoplastic polyolefin (TPO) or heterophasic copolymer (HECO). In some embodiments, the compatibilizer is reactor-produced TPO (rTPO) or reactor-produced HECO. The propylene-based compatibilizer improves the compatibility of the virgin material with the PCR polyolefin by increasing the interfacial strength between the components and improving the dispersion of the components. This changes the molecular properties and allows for a broader application of the novel composition.

[0057] In some embodiments, the novel compositions have improved impact resistance with little or no loss of stiffness. In other embodiments, the use of a propylene-based compatibilizer improves notched Izod impact strength by at least 10% compared to a composition without a compatibilizer. In other embodiments, the use of a propylene-based compatibilizer can improve notched Izod impact strength by at least 10% compared to a composition without a propylene-based compatibilizer while maintaining flexural modulus. In other embodiments, the use of a propylene-based compatibilizer improves notched Izod impact strength by at least 10% compared to a composition without a propylene-based compatibilizer, but reduces flexural modulus by less than 20% compared to a composition without a propylene-based compatibilizer. In other embodiments, the use of a propylene-based compatibilizer allows the user to adjust the ratio of impact to stiffness (notched Izod to flexural modulus).

[0058] To reduce the environmental impact of polyolefin waste, consumer products made with polyolefins are recycled and reused. However, many PCR materials have poorer physical and mechanical properties than virgin materials because the polymer chains during PCR are broken by repeated heating and shearing of the polyolefins in the extruder, exposure to UV light, and stress cracking. For this reason, PCR polyolefins are often combined with virgin resins to improve physical properties.

[0059] Although some improvements have been made, there have been some challenges when combining PCR and virgin polyolefins. For example, if the PCR polyolefin is not the same type of polyolefin as the virgin polyolefin, the two components may not blend completely. Specifically, the two different polyolefins may phase separate in the melt state, creating structural weaknesses in the resulting material. Even if the PCR polyolefin and virgin polyolefin are the same type of polyolefin, the PCR polyolefin may have small amounts of one or more "impurities" in the form of different polyolefins or other polymers that cause phase separation.

[0060] The compositions disclosed herein solve these problems by using a propylene-based compatibilizer, such as TPO or HECO, to improve both the dispersion and the interface between the virgin material and the PCR polyolefin. In some embodiments, the HECO or TPO compatibilizer in the composition has at least one component that is compatible with both the PCR polyolefin and the virgin material. In other embodiments, when the PCR and virgin polyolefins are not the same polyolefin, the HECO or TPO compatibilizer in the composition has a component that is compatible with the PCR polyolefin and a component that is compatible with the virgin material. This makes the blend composition more stable and reduces phase separation.

[0061] In addition, the propylene-based compatibilizer can modify the physical and mechanical properties of the blend, which allows the propylene-based compatibilizer to be selected to obtain the desired properties in the final composition, thus increasing the application range of the blend.

[0062] More specifically, the compositions described herein include (1) at least one virgin polyolefin, (2) at least one PCR olefin, and (3) a propylene-based compatibilizer, which may be TPO or HECO, including reactor produced TPO and HECO. The compositions of the present disclosure can be extruded or molded into articles that have physical properties (durability, flexural strength, flexural modulus, impact resistance) that allow for a variety of applications, such as caps, closures, low pressure pipes, bags, sheets, fibers, packaging, films, etc.

[0063] Virgin polyolefin: The compositions disclosed herein include at least one virgin polyolefin. All types of PE, PP, and other C4-C 10 Any virgin polyolefin can be used in the compositions of the present disclosure that include an α-olefin.

[0064] The total amount of virgin polyolefin in the composition of the present disclosure is from about 5 to about 85% by weight, based on the weight of the composition. In some embodiments, the total amount of virgin polyolefin present is between about 5% and about 45%, between about 30% and about 65%, between about 55% and about 85%, between about 45% and about 75% by weight.

[0065] In some embodiments, the virgin polyolefin is a homopolymer with a MFR greater than 2 g / 10 min (230° C. / 2.16 kg), greater than 50 g / 10 min (230° C. / 2.16 kg), greater than 100 g / 10 min (230° C. / 2.16 kg), or greater than 1500 g / 10 min (230° C. / 2.16 kg). In other embodiments, the virgin polyolefin is a homopolymer with high hardness. In other embodiments, the virgin polyolefin has a flexural modulus (ASTM D790) (1.3 mm / min, 1% secant, Procedure A) of about 240 to about 300 kPSI, about 290 kPSI (2000 MPa), a notched Izod impact strength (73°F, Method A) of about 0.3 to about 1 ft-lb / In, about 0.3 ft-lb / In, a tensile yield strength (2 in / min) of about 2800 psi to about 6200, about 5000 psi to about 6200 psi, or about 6100 psi, and a yield elongation of about 5% to about 9%, or about 6%. In other embodiments, the xylene soluble content of the virgin polyolefin is 1 to about 5 wt.%. In any of these embodiments, the virgin polyolefin is a PP or PE homopolymer.

[0066] In alternative embodiments, the virgin polyolefin comprises (A) about 50-95 wt. % of a crystalline propylene homopolymer having a solubility in xylene of 1-3% at room temperature, and (B) about 5-50 wt. % of a partially amorphous copolymer of ethylene and propylene, the ethylene content being about 20% to less than 100%, and the intrinsic viscosity of the xylene soluble fraction of the copolymer being about 2-5 dL / g (in decane). In these alternative embodiments, the MFR of the crystalline propylene homopolymer of the virgin polyolefin is about 100 to about 300 g / 10 min.

[0067] In other embodiments, a combination of virgin polyolefins having different MFRs is used. For example, a virgin polyolefin having a low MFR can be combined with a virgin polyolefin having a high MFR to obtain a composition having an MFR between the two. In some embodiments, a virgin polyolefin having an MFR between 20 and 80 g / 10 min (230° C. / 2.16 kg) can be combined with a virgin polyolefin having an MFR between 500 and about 2500 g / 10 min (230° C. / 2.16 kg) to obtain a polyolefin composition having an MFR of at least more than 20 g / 10 min (230° C. / 2.16 kg) and less than 2500 g / 10 min (230° C. / 2.16 kg). PCR Olefin:

[0068] The compositions disclosed herein include at least one post-consumer recycled polyolefin, which may be ground into granules or flakes and then combined with a propylene-based compatibilizer and virgin resin in an extrusion hopper.

[0069] All types of PE, PP and C4-C 10PCR polyolefins can be used in the compositions of the present disclosure that include α-olefins. In some embodiments, the PCR polyolefins can include a single polyolefin. In other embodiments, the PCR polyolefins can include a combination of polyolefins. Also, the PCR polyolefin resins can be recycled high or low density PE.

[0070] The total amount of PCR polyolefin in the composition of the present disclosure is about 5% by weight. % to about 85% by weight. % is based on the weight of the composition. In some embodiments, the total amount of PCR polyolefin present is about 5% by weight and about 45% by weight, about 30% by weight and about 65% by weight, about 55% by weight and about 85% by weight, about 15% by weight and about 45% by weight, or 5, 10, 15, 20, 25, 40 or 50% by weight.

[0071] In some embodiments, the PCR polyolefin resin can have a melt index (MI) of about 0.3 to about 1, or about 0.3 to 0.7, or about 0.6 to 1, or about 0.4 to 0.8. In other embodiments, the PCR polyolefin resin can have a melt index (MI) of about 0.940 to about 0.970 g / cm. 3 or about 0.940 to about 0.960 g / cm 3 or about 0.950 to about 0.970 g / cm 3 or about 0.945 to about 0.965 g / cm 3 The density of the powder may be 0.01 to 0.01.

[0072] In some embodiments, the PCR polyolefin resin has an MI of about 0.3 to about 1 and a density of about 0.940 to about 0.970 g / cm 3 This is PE.

[0073] Compatibilizer: The compositions disclosed herein further include at least one propylene-based compatibilizer. Such propylene-based compatibilizer may be TPO or HECO, including reactor-produced TPO and HECO. Both TPO and HECO have a semi-crystalline polypropylene matrix component and a rubber component, with the proviso that the rubber content in HECO is less than 30% and the rubber content in TPO is 30% or more.

[0074] In the compositions described herein, the total amount of HECO or TPO compatibilizer is about 10 to about 50 weight percent, or about 10 to about 40 weight percent, based on the weight of the composition. In some embodiments, the total amount of compatibilizer present is about 10 weight percent and about 27 weight percent, about 20 weight percent and about 35 weight percent, about 15 weight percent and about 29 weight percent, or about 15 to about 20 weight percent.

[0075] Propylene-based, but other C2-C 10 HECO or TPO compatibilizers made with the components can be used in the methods described herein.

[0076] In some embodiments, the propylene-based compatibilizer comprises a semi-crystalline polypropylene-based matrix and a bipolymer or terpolymer as the rubber component, the rubber component being 30% by weight or more (≧30) of the TPO or rTPO compatibilizer. In some embodiments, the TPO or rTPO compatibilizer has a propylene homopolymer or random copolymer with ethylene (RACO) as the semi-crystalline matrix mixed with the biopolymer or terpolymer. In some embodiments of the composition of the present disclosure, the bipolymer or terpolymer is a mixture of propylene and ethylene or C4-C 10 In some embodiments, the TPO or rTPO includes a bipolymer as the rubber component, the biopolymer being a combination of ethylene and a C4-C olefin such as butene. 10Alternatively, TPO or rTPO may contain a terpolymer as the rubber component, which is a combination of propylene and ethylene comonomers and a C4-C olefin comonomer such as butene. 10 In combination with an α-olefin comonomer.

[0077] In yet another embodiment, the compatibilizer is a rTPO having PE and PP components. Alternatively, the compatibilizer is a PP component and a C4-C 10 and rTPO having an α-olefin component.

[0078] In other embodiments, the compatibilizer is a reactor produced HECO compatibilizer comprising a semi-crystalline polypropylene based matrix and a bipolymer or terpolymer as the rubber component, said rubber component being less than 30% by weight of the HECO compatibilizer. In some embodiments, the HECO compatibilizer comprises a propylene homopolymer or random copolymer (RACO) with ethylene as the semi-crystalline matrix mixed with a biopolymer or terpolymer. In some embodiments of the compositions of the present disclosure, the bipolymer or terpolymer comprises propylene and ethylene or C4-C 10 In some embodiments, the HECO comprises a bipolymer as the rubber component, the biopolymer being a combination of ethylene and a C4-C olefin such as butene. 10 Alternatively, HECO contains a terpolymer as the rubber component, which is a combination of propylene and ethylene comonomers and a C4-C olefin comonomer such as butene. 10 In combination with an α-olefin comonomer.

[0079] The amount of propylene comonomer in the rubber component of the HECO or TPO compatibilizer may vary from about 0% to less than 100% by weight of the rubber component, in some embodiments, the amount of propylene comonomer in the rubber component is from about 0 to about 45%, from about 30 to about 65%, from about 50 to about 80%, or from about 75 to less than 100% by weight.

[0080] The amount of rubber in the HECO compatibilizer may vary from about 5% to up to 30% by weight relative to the HECO, in some embodiments the amount of rubber is from about 5 to about 20%, up to about 15-30%, or less than about 10-30% by weight relative to the HECO compatibilizer.

[0081] The amount of rubber in the rTPO compatibilizer may vary from 30 to about 80% by weight relative to the rTPO, hi some embodiments, the amount of rubber is 30 to about 55%, about 50 to about 80%, 30 to about 45%, or 50 to about 75% by weight relative to the rTPO compatibilizer.

[0082] In one embodiment, the compatibilizer may be a propylene-based rTPO having an MFR of 0.35-1 g / 10 min and an intrinsic viscosity of the xylene soluble fraction of about 4 dl / g-6 dl / g (in decamethylolpropane). The propylene-based rTPO compatibilizer may be (A) a propylene homopolymer, a propylene random copolymer containing up to 8% ethylene, up to 8% of at least one C4-C 10 (B) a semi-crystalline polypropylene component selected from the group consisting of propylene random copolymers containing α-olefins, or any combination thereof, the semi-crystalline polypropylene component having a monomodal molecular weight distribution being about 30% to less than 70%; and (C) a copolymer of propylene and ethylene and / or C4-C 10 and more than 30% to about 70% of a bipolymer component with at least one comonomer selected from α-olefins, the bipolymer itself having about 50% to 75% propylene, the bipolymer being partially soluble in xylene at room temperature and having an intrinsic viscosity of about 4 to 7.5 dL / g (in decane).

[0083] In another embodiment, the compatibilizer may include a propylene-based rTPO as a rubber component having (A) about 25 to 50% by weight of a crystalline propylene homopolymer having a solubility in xylene of 4% or less at room temperature, or a crystalline copolymer of propylene and ethylene or a C4-C8 α-olefin having an ethylene or α-olefin content of 0.5 to 3% and a solubility in xylene of 2 to 10% at room temperature, and (B) about 50 to 75% by weight of a partially amorphous copolymer of ethylene and a C4-C8 α-olefin having an α-olefin content of 10 to 20% and being soluble in xylene at room temperature by about 10 to 40%.

[0084] In one embodiment, the polypropylene-based compatibilizer may have (A) about 50 to 95% by weight of a crystalline propylene homopolymer having a solubility in xylene at room temperature of 1 to 3% and, optionally, an MFR of about 20 to about 200 g / 10 min, about 20 to about 100 g / 10 min, or about 100 to about 200 g / 10 min, and (B) about 5 to 50% by weight of a partially amorphous copolymer of ethylene and propylene as a bipolymer rubber component having an ethylene content of about 20% to less than 100% and an intrinsic viscosity of the xylene-soluble fraction of about 2 to 5 dl / g (in decamethylphenyl) .

[0085] In one embodiment, the polypropylene-based compatibilizer may have (A) about 50 to 95% by weight of a crystalline propylene homopolymer having a solubility in xylene at room temperature of 1 to 3% and, optionally, an MFR of about 2 to about 200 g / 10 min, and (B) about 5 to 50% by weight of a partially amorphous copolymer of ethylene and propylene as a bipolymer rubber component having an ethylene content of about 20% to less than 100% and an intrinsic viscosity of the xylene soluble fraction of about 2 to 5 dl / g (in decane).

[0086] In one embodiment, the polypropylene-based compatibilizer may have (A) about 50 to 95% by weight of a crystalline propylene homopolymer having a solubility in xylene at room temperature of 1 to 3% and an MFR of about 2 to about 20 g / 10 min, and (B) about 5 to 50% by weight of a partially amorphous copolymer of ethylene and propylene as a bipolymer rubber component having an ethylene content of about 20% to less than 100% and an intrinsic viscosity of the xylene soluble fraction of about 2 to 5 dl / g (in decane).

[0087] In yet another embodiment, the polypropylene-based compatibilizer is a TPO having components (A) and (B), the amount of (A) and (B) being the total weight of (A) and (B), and the viscosity value [η] of the xylene-soluble fraction at room temperature is 7 to 9 dl / g (in tetralin). Components (A) and (B) are as follows:

[0088] (A) comprises, based on the total weight of (A), 25 to 75 wt. % of a propylene polymer (AI) having a melt flow rate value MFRI of 1.2 g / 10 min and 25 to 75 wt. % of a propylene polymer (AII) having a melt flow rate value MFRII of 73 g / 10 min (AII), the MFRII / MFRI ratio being 60, and the propylene polymer (AI) and the propylene polymer (AII) being independently selected from a propylene homopolymer, a propylene random copolymer containing up to 3% ethylene, and up to 6% of at least one C4-C 10 70% of a semi-crystalline matrix selected from the group consisting of propylene random copolymers containing α-olefins and optionally up to 3% ethylene, the amount of (AI) and (AII) being the total weight of (AI) and (AII), the semi-crystalline matrix having a polydispersity index of 4 to 7; (B) Ethylene and at least one C3-C 10 and 30% rubber, including copolymers with alpha-olefins, the copolymer or terpolymer being 36% ethylene.

[0089] In one embodiment, the propylene-based compatibilizer may comprise: (AI) about 25-75% by weight of a semi-crystalline propylene homopolymer having a solubility in xylene at room temperature of 2-4% and a MFR of 60-160 g / 10 min; (AII) about 5-40% by weight of a high density polyethylene having a MFR of 40-140 g / 10 min; and (B) about 5-50% by weight of a partially amorphous copolymer of ethylene and propylene as a bipolymer rubber having an ethylene content of about 20-100% and an intrinsic viscosity of the xylene soluble fraction of about 2-4 dl / g (in decamethylphenyl) .

[0090] In one embodiment, the propylene-based compatibilizer may have a component (A) including (AI) about 25-75% by weight of a crystalline propylene homopolymer having a solubility in xylene at room temperature of less than 3% and an MFR of 2-20 g / 10 min, and (AII) about 5-40% by weight of a crystalline propylene homopolymer having an MFR of 40-140 g / 10 min, and a component (B) of about 5-50% by weight of a partially amorphous copolymer of ethylene and propylene as a bipolymer rubber component, the ethylene content of which is about 20-100% and the intrinsic viscosity of the xylene soluble fraction is about 2-4 dl / g (in decane).

[0091] In another embodiment, the propylene-based compatibilizer has an MFR of 0.35 to 35 g / 10 min, and the propylene-based compatibilizer is a component (A) propylene homopolymer having an isotactic index of more than 80, or a mixture of more than 85 wt. % propylene and (i) ethylene, (ii) C H2 =CHR α-olefin or a copolymer of (i) and (ii) in a combination, component (A) containing 10 to 60 parts by weight, component (BI) containing 5 to 20 parts by weight of a copolymer fraction insoluble in xylene at ambient temperature and containing ethylene, and a copolymer fraction of ethylene and (i) propylene, (ii) other C H2and component (BII) having 37-80 parts by weight of a copolymer fraction of an α-olefin, where R is a carboalkyl group of 2-8, or a combination of (i) and (ii) and any minor portion of a diene, component (BII) being less than 40% by weight of ethylene, soluble in xylene at ambient temperature, having an intrinsic viscosity of about 1.5-5 dl / g, the sum of components (BII) and (BII) being about 40-90% based on the total weight percent of the polyolefin composition, and the weight ratio of (BI) / (BII) being less than 0.4. Components (BI) and (BII) constitute the rubber component of this compatibilizer.

[0092] In some embodiments, the propylene-based compatibilizer is a reactor-produced heterophasic thermoplastic olefin copolymer, where propylene homopolymer or random copolymer with ethylene (RACO) is mixed with the bipolymer. In other embodiments, the compatibilizer is a reactor-produced heterophasic thermoplastic olefin terpolymer containing three components: AI) semi-crystalline propylene homopolymer or random copolymer with ethylene or other α-olefin, AII) polyethylene homopolymer, polypropylene homopolymer, or polyethylene copolymer with 1-butene or other α-olefin, and B) an elastic rubber component consisting of a copolymer of propylene and ethylene.

[0093] In any of the above compatibilizers, the α-olefin may be selected from the group including 1-butene, 1-pentene, 1-hexene, 4-methyl-1-pentene, and 1-octene.

[0094] All the above propylene-based compatibilizers are exemplary and show the wide range of formulation changes to allow the use of TPO and HECO resins (including reactor-produced TPO and HECO resins) as compatibilizers in general. In addition to the above formulas, the propylene-based compatibilizer for the present composition can also contain any of the formulas described in US5286564, each of which is incorporated herein in its entirety for all purposes. The propylene-based compatibilizer can also be produced by any of the reactor methods described in US2009015678, US7592393, US8008400, EP1025169, EP0640648, EP0472946, EP1687372, WO2016207235, WO2016207236, and US2012184675A.

[0095] In yet another embodiment, the propylene-based compatibilizer is an rTPO or HECO prepared using a multi-stage gas phase polymerization process that creates an alloy between the rubber component (biopolymer or terpolymer) and the polymer matrix (e.g., semi-crystalline PP backbone) in the reactor, allowing for uniform dispersion of the rubber component throughout the polymer matrix as both occur simultaneously during polymerization. Examples of commercially available compatibilizers for use in the compositions of the present application include, but are not limited to, rTPO from LyondellBasell (Houston, TX) and the Pro-fax, Adflex and Hifax series from HECO.

[0096] Optional Additives: In addition to the virgin resin, PCR resin, and compatibilizer, the composition can contain optional additives that impart color, including dyes, pigments, or other materials that impart color to the polymer composition and subsequent products, and can contain materials that impart metallic or pearlescent effects.

[0097] Additionally, the composition may contain antioxidants, nucleating agents, slip agents, UV light stabilizers, anti-scratch agents, or other necessary additives depending on the end use of the composition and / or the article. Goods:

[0098] The present disclosure also includes embodiments of the articles and methods of forming the articles.

[0099] Some embodiments of the present disclosure relate to articles made using any of the above compositions, or each embodiment relates to an article made using any of the above compositions, the article being in the form of a sheet, film, pipe, strand, tube, container, pellet, or custom profile specific to a particular application.

[0100] Some embodiments of the present disclosure are methods of making articles with any of the compositions described above, including dry blending virgin resin, compatibilizer, and PCR resin, melting the composition at a known temperature, and extruding the composition through a die. In some methods, the dry blending and melting process occurs in the extruder hopper.

[0101] In some embodiments, methods of making a compression molded cap or closure are provided herein. Applicant currently believes that the compositions described herein can be compression molded into a cap or closure. The compositions described herein can have a die swell sufficient to make a cap or closure. In one embodiment, the compositions described herein have a die swell such that the composition does not well into a "mushroom top" after being sliced ​​from the extrudate and before being transferred to a compression die.

[0102] Physical properties:

[0103] The compositions and articles formed therewith may have the following physical properties:

[0104] MFR In some embodiments, the MFR (ASTM D1238L) (230°C / 2.16 kg) of the polyolefin composition is about 4 to about 35 g / 10 min, about 15 to about 35 g / 10 min, about 15 to about 30 g / 10 min, about 25 to about 35 g / 10 min, or about 20 to about 30 g / 10 min.

[0105] Flexural modulus In some embodiments, the flexural modulus (ASTM D 790) (1.3 mm / min, 1% secant, Procedure A) of the polyolefin composition is about 155 to about 300 kPSI, about 160 to about 300 kPSI, about 160 to about 170 kPSI, about 170 to about 300 kPSI, about 170 to about 270, about 200 to about 270 kPSI (about 1378 to 1860 MPa), about 200 to about 250 kPSI, about 240 to about 270 kPSI, or about 215 to about 240 kPSI.

[0106] Tensile Yield Strength In some embodiments, the polyolefin composition has a tensile yield strength (ASTM D638) of at least 3700 psi, at least 4000 psi (-27 MPa), from about 4000 to about 5000 psi, from about 4000 to about 4400 psi, or from about 4300 to about 4800 psi.

[0107] Yield elongation In some embodiments, the polyolefin composition has a yield elongation of about 3 to about 10%, about 3 to 7%, about 6 to 10%, about 4% to about 9.5, or about 7% to about 7.5%.

[0108] Tensile Break Strength In some embodiments, the polyolefin composition has a tensile strength (ASTM D638) of at least about 190 psi, at least 2000 psi (-14 MPa), from about 2000 to about 5000 psi, from about 2000 to about 3200 psi, or from about 3000 to about 4800 psi.

[0109] Breaking Elongation In some embodiments, the polyolefin composition has an elongation at break of about 3% to greater than 200%, about <247> 3% to approximately 60%, approximately 3 to 45%, approximately 35 to 60%, approximately 3 to 10%, and approximately 30% to approximately 50%.

[0110] Notched Izod Impact Strength at 73°F In some embodiments, the polyolefin composition has a notched Izod impact strength at 73°C (ASTM D 256) of about 0.4 to about 12 ft-lb / in, about 1.5 to about 4 ft-lb / in, about 0.4 to about 1.5 ft-lb / in, about 0.4 to 0.8 ft-lb / in, about 0.7 to 1.1 ft-lb / in, about 0.9 to 1.5 ft-lb / in, or about 0.7 to 1.2 ft-lb / in. Working Example

[0111] The following examples are included to illustrate the embodiments of the appended claims that use the above compositions. These examples are for illustrative purposes and are not intended to unduly limit the scope of the appended claims. Those skilled in the art will understand that various modifications can be made to the specific embodiments disclosed without departing from the spirit and scope disclosed herein, and still obtain the same or similar results. The following examples should not be understood in any way as limiting or defining the scope of the appended claims.

[0112] This example shows the change in physical properties due to the addition of HECO or TPO compatibilizers to PCR / virgin resin blends. The formulations of the compositions and their comparative (no compatibilizer) compositions are shown in Table 1, with weight percentages calculated using the total weight of each composition.

[0113] The components of these compositions are as follows:

[0114] Base Virgin Resins: Four different virgin polypropylene resins from LyondellBasell (Houston, TX) are used in each example. Each example has at least one virgin resin, but most examples use a combination of them.

[0115] Virgin Resin A (VRA) is a PP homopolymer resin with a very narrow molecular weight distribution and a very high melt flow rate. The melt flow rate of VRA is 1800g / 10min (230℃ / 2.16kg). The ultra-high melt flow rate can reduce the processing temperature and save energy. This resin is added to some compositions of this application to further improve the MFR of the blend to a target MFR of about 20.

[0116] Virgin Resin B (VRB) is a nucleated polypropylene homopolymer with a high melt flow rate. The melt flow rate of VRB is 65g / 10min (230°C / 2.16kg). The flexural modulus (ASTM D 790) (1.3mm / min, 1% secant, procedure A) of VRB is approximately 290kPSI (2000MPa), the notched Izod impact strength (73°F, method A) is 0.3ft-lb / in, the tensile yield strength (2in / min) is 6100ps / in, and the yield elongation is 6%. Thus, VRB is already being used as a building block for applications requiring high flow and high stiffness.

[0117] Virgin Resin C (VRC) is a low melt flow rate polypropylene homopolymer. The melt flow rate of VRC is 2.3 g / 10 min (230°C / 2.16 kg). The flexural modulus (ASTM D790) of VRC (1.3 mm / min, 1% secant, procedure A) is about 275 kPSI (1900 MPa), the notched Izod impact strength (73°F, method A) is 1.0 ft-lb / in, and the tensile yield strength (2 in / min) is 5400 psi. This resin is added to some compositions of the present disclosure to modestly increase the MFR of the blend to a target MFR of about 4 to about 12.

[0118] Virgin Resin D (VRD) is a polyolefin having (A) about 87% by weight of a crystalline propylene homopolymer having a solubility in xylene of about 2% at room temperature, and (B) about 13% by weight of a partially amorphous copolymer of ethylene and propylene having an ethylene content of about 57% and an intrinsic viscosity of the xylene-soluble fraction of the copolymer of about 2.4 dl / g in decane. The MFR of the crystalline propylene homopolymer of VRD is about 185 g / 10 min. PCR Resin: The PCR resin used in the examples is high density polyethylene (HDPE) from recycled milk tanks. HDPE milk tanks are cleaned, crushed and granulated.

[0119] Compatibilizers: Eight compatibilizers from LyondellBasell (Houston, TX) are used in each example. These compatibilizers are reactor-produced HECO or TPO that contain polymer chains composed of PP, PE, and butene moieties.

[0120] Compatibilizer A (CA) is a compatibilizer having (A) about 77% by weight of a crystalline propylene homopolymer having a solubility in xylene at room temperature of about 2% and (B) about 23% by weight of a partially amorphous copolymer of ethylene and propylene having an ethylene content of about 44% and an intrinsic viscosity of the xylene-soluble fraction of the copolymer of about 4 dl / g (in decamethylolpropane). Compatibilizer A has a MFR of about 12 g / 10 min for the crystalline propylene homopolymer.

[0121] Compatibilizer B (CB) is a compatibilizer having (A) about 79% by weight of a crystalline propylene homopolymer having a solubility in xylene of 2.3% at room temperature and (B) about 21% by weight of a partially amorphous copolymer of ethylene and propylene having an ethylene content of about 44% and an intrinsic viscosity of the xylene-soluble fraction of the copolymer of about 4 dl / g (in decamethylenol). Compatibilizer B has a MFR of about 150 g / 10 min for the crystalline propylene homopolymer.

[0122] Compatibilizer C (CC) is a compatibilizer containing 70% (A) and 30% (B), where the (A) polypropylene component contains, relative to the total weight of (A), 50% by weight of (AI) a propylene homopolymer having a melt flow rate MFRI of less than 5 g / 10 min and 50% by weight of (AII) a propylene homopolymer having a melt flow rate value MFRII higher than 50 g / 10 min, with an MFRII / MFRI ratio of 60, and (B) a copolymer of ethylene and propylene, with 36% ethylene. The viscosity [η] of the xylene soluble fraction of compatibilizer C at room temperature is about 8.2 dl / g (tetrahydronaphthalene).

[0123] Compatibilizer D (CD) is an rTPO containing (AI) about 54% by weight of a crystalline propylene homopolymer having a solubility in xylene at room temperature of 2-4% and an MFR of 60-160 g / 10 min, (AII) about 11% by weight of high density polyethylene, and (B) about 35% by weight of a partially amorphous copolymer of ethylene and propylene having an ethylene content of about 48% and an intrinsic viscosity of the xylene soluble fraction of the copolymer of about 3.2 dl / g (in decane). The MFR of the combination of AI and AII in CD is about 90 g / 10 min.

[0124] Compatibilizer E (CE) is an rTPO containing (AI) about 32.5% by weight of a crystalline propylene homopolymer having a solubility in xylene at room temperature of less than 3% and an MFR of about 2 to about 20 g / 10 min, (AII) about 31% by weight of a crystalline propylene homopolymer having an MFR of about 600 to 1000 g / 10 min, and (B) about 36.5% by weight of a partially amorphous copolymer of ethylene and propylene having an ethylene content of about 52% and an intrinsic viscosity of the xylene-soluble fraction of the copolymer of about 2.8 dl / g (in decane). The MFR of the combination of AI and AII in CE is about 85 g / 10 min.

[0125] Compatibilizer F (CF) is an rTPO that includes (A) about 30% by weight of a crystalline propylene homopolymer having a solubility in xylene at room temperature of 4% or less, and (B) about 70% by weight of a partially amorphous copolymer of ethylene and butene, having a butene content of about 16% and being about 20% soluble in xylene at room temperature.

[0126] Compatibilizer G (CG) is an rTPO having an MFR of about 0.8 G / 10 min and an intrinsic viscosity of the xylene soluble fraction of about 5 dl / G (in decane). Compatibilizer G has (A) about 50% semicrystalline propylene homopolymer and (B) about 50% bipolymer component of propylene and ethylene, the bipolymer itself having about 50% to about 75% propylene.

[0127] Compatibilizer H(CH) has (A) about 74% by weight of a crystalline propylene homopolymer having a solubility in xylene of about 2% at room temperature, and (B) about 26% by weight of a partially amorphous copolymer of ethylene and propylene having an ethylene content of about 51% and an intrinsic viscosity of the xylene-soluble fraction of the copolymer of about 3 dl / g (in decane). Compatibilizer H has a MFR of 56 g / 10 min for the crystalline propylene homopolymer.

[0128] [Table 2-1] [Table 2-2]

[0129] Physical Properties: Each blend in Table 1 is evaluated according to the methods disclosed in "Test Methods" above. The results of Comparative Examples 1-4 and Examples 1-23 of the compositions are shown in Table 2. [Table 3-1] [Table 3-2]

[0130] It can be seen from Table 2 that the physical properties change as compared with Comparative Compositions 1 to 4 due to the addition of the compatibilizer.

[0131] The notched Izod test measures a material's resistance to pendulum impact. Many of the examples have higher notched Izod values ​​compared to Comparative Compositions 1-4, indicating that the exemplary compositions are more impact resistant. The compatibilizer improves notched Izod impact strength by at least 10% compared to Comparative Composition 1 (Example 6). However, most examples improve notched Izod impact by 90%.

[0132] The flexural modulus of a material is a physical property that describes the ability of the material to bend. Flexural modulus measurements are shown in Table 2. Many of the examples have lower flexural moduli, indicating that the exemplary compositions are more flexible, as compared to Comparative Compositions 1-4. The decrease in flexural modulus is less than about 20%.

[0133] The yield and break tensiles of each example are also lower than those of Comparative Compositions 1-4. However, the elongations are the same or higher. This indicates that the presently disclosed compositions are more likely to break upon elongation. Furthermore, the wide range of elongations indicates that it is possible to use compatibilizers to modify physical properties for various applications.

[0134] The examples show that the compatibilizer can significantly increase notched Izod impact strength by more than 90% while maintaining or decreasing flexural modulus by no more than about 10%.

[0135] In each example, blends of virgin PP and PE PCR in the range of 5% to 40% (without compatibilizer as provided in each comparative example) are shown to produce flexural modulus / notched Izod values ​​in the range of 668 to 770 kPSI / ft-lb / in. In each example, the use of a compatibilizer (either CA, CB, CC, CD, CE, CF, CG, CH or CI) in the range of 5% to 40% of PP and PE PCR are shown to produce flexural modulus / notched Izod values ​​of about 10 to about 650 kPSI / ft-lb / in, about 15 to about 622 kPSI / ft-lb / in, about 150 to about 300 kPSI / ft-lb / in, and about 175 to about 280 kPSI / ft-lb / in.

[0136] These results from each sample demonstrate that multiple HECO and TPO compatibilizers, including those produced using the reactor system, can alter the properties of compositions containing post-consumer recycled polyolefin waste. These examples use virgin PP and PCR PE resins, but other C2-C 10 Similar results are seen with polyolefins.

[0137] The exemplary compositions exhibit a wide range of physical properties, allowing for a wide range of applications. For example, based on their properties shown in Table 2, compositions 1, 2, 5, 9 and 12 may be suitable for cap and closure applications. However, the remaining compositions may be used for other applications such as low pressure pipes, bags, sheets, slatted boxes, containers, packaging or films.

[0138] The die swell of Example 1 is measured with a capillary rheometer as described in "Test Methods". The die swell ratio of Example 1 is plotted against apparent shear rate 1 / s. The results are graphed in FIG. 1 below. The graph in FIG. 1 also includes the die swell ratio of HDPE having an MFR of 21 g / 10 min and the die swell ratio of a composition blend having HDPE and 25% HDPE PCR having an MFR of 16 g / 10 min, each of which is plotted independently against apparent shear rate 1 / s. Applicant currently believes that the blend composition of PP and HDPE PCR compatibilized has a smaller or improved die swell ratio compared to virgin HDPE of approximately the same MFR, sufficient for use in compression molding processes to manufacture caps and closures.

[0139] In various embodiments, a compression molded cap or closure is provided, the composition of the cap or closure having a first melt flow rate and a first die swell ratio at a given shear rate, the first melt flow rate being within 10% of a second melt flow rate of virgin HDPE, the first die swell ratio at the given shear rate being from 0% to less than 25% of the second die swell ratio at the given shear rate of virgin HDPE, and the second die swell ratio at the given shear rate and the second die swell ratio are the same HDPE values. The following references are all incorporated herein by reference:

[0140] ASTM D1238L, Standard Test Method for Determining Melt Flow Rate of Thermoplastics Using an Extrusion Plasmometer ASTM D790-03, Standard Test Method for Flexural Properties of Unreinforced and Reinforced Plastics and Electrical Insulating Materials ASTM D638-03, Standard Test Method for Tensile Properties of Plastics ASTM D256-06, Standard Test Method for Determining the Izod Pendulum Impact Resistance of Plastics ASTM D1505-18, Standard Test Method for Density of Plastics by Degree Gradient Method (ASTM International, West Conshohocken, PA, 2018) ASTM D5492-17, Standard Test Method for Determination of Xylene Solubles in Propylene Plastics (ASTM International, West Conshohocken, PA, 2017) ITM 20061, Infrared spectrophotometric determination of ethylene content in semi-crystalline propylene-ethylene copolymers ISO 1628-1, Plastics - Determination of viscosity of polymers in dilute solution using a capillary viscometer US7592393 US8008400 EP1025169 EP0640648 EP0472946 WO2016207235 WO2016207236 US2009015678 US2012184675A

Claims

1. 1. A composition comprising: (i) a virgin resin having a first polyolefin; (ii) a post-consumer recycled resin having a second polyolefin; and (iii) a polypropylene-based compatibilizer, (A) 25 to 75 wt. % of a propylene polymer (AI) having a melt flow rate value MFRII (230°C / 2.16 kg) of 1.2 g / 10 min, based on the total weight of (A), and 25 to 75 wt. % of a propylene polymer (AII) having a melt flow rate value MFRII (230°C / 2.16 kg) of 73 g / 10 min, based on the total weight of (A), wherein the propylene polymer (AI) and the propylene polymer (AII) are independently selected from a propylene homopolymer, a propylene random copolymer containing up to 3% ethylene, and up to 6% of at least one C ４ -C １０ 70% of a semi-crystalline matrix selected from the group consisting of random copolymers of propylene containing α-olefins and optionally up to 3% ethylene, the amount of (AI) and (AII) being relative to the total weight of (AI) and (AII), and having a polydispersity index of 4 to 7; (B) Ethylene and at least one C ３ -C １０ 30% of a rubber comprising a copolymer with an α-olefin and having an ethylene content of 36%; Including, The amounts of (A) and (B) are based on the total weight of (A) and (B), and the composition has a viscosity value [η] of a xylene-soluble fraction at room temperature of 7 to 9 dl / g.

2. 2. The composition of claim 1, having a flexural modulus of 1069 to 2069 MPa and a notched Izod impact of 21.36 to 640.8 J / m at 23° C., said flexural modulus / notched Izod impact value being in the range of 1.29 to 83.9 MPa / J / m.

3. The composition according to claim 1, wherein (i) has an MFR (230° C. / 2.16 kg) of 2 to 200 g / 10 min.

4. 13. An article formed from the composition of claim 1.

5. A composition comprising: (i) a virgin resin having a first polyolefin; (ii) a post-consumer recycled resin having a second polyolefin; and (iii) a polypropylene-based compatibilizer, (A) AI) 25 to 75% by weight of a propylene homopolymer having a melt flow rate MFRI (230° C. / 2.16 kg) of 1.2 g / 10 min, based on the total weight of (A); and AII) 25 to 75% by weight of a propylene homopolymer having a melt flow rate value MFRII (230°C / 2.16 kg) of 73 g / 10 min, based on the total weight of (A); a semi-crystalline matrix comprising: (B) a rubber comprising a copolymer of ethylene and butene, the ethylene content of the copolymer being 36%; and A composition comprising:

6. 6. The composition of claim 5, having a flexural modulus of 1069 to 2069 MPa and a notched Izod impact at 23° C. of 21.36 to 640.8 J / m, said flexural modulus / notched Izod impact value being in the range of 1.29 to 83.9 MPa / J / m.

7. The composition according to claim 5, wherein the MFR (230°C / 2.16 kg) of (i) is 2 to 200 g / 10 min.

8. An article formed from the composition of claim 5.

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