ITEM MANUFACTURED FROM POST-CONSUMER RESIN WITH A SMOOTH SURFACE FINISH

Abstract

This description provides a process. In one embodiment, the process includes providing pellets of a ground material. The ground material is a post-consumer recycled multilayer film (PCR multilayer film) having at least three layers. The PCR multilayer film comprises (i) a polyethylene layer, (ii) a polyamide layer, and (iii) a coextrusion adhesive. The coextrusion adhesive comprises substantially linear ethylene polymer grafted with maleic anhydride (MAH-g-SLEP) having an Mw / Mn ratio of 1.5 to less than 3.5 and a melt index of 0.5 g / 10 min to less than 25 g / 10 min. The process includes extruding the pellets to form an extrudate, molding the extrudate, and forming, with the extrudate, a molded article having a surface. The surface of the molded article has a surface roughness value, Sa, of less than 1000 nm and a mean square roughness value, Sq, of less than 1400 nm.

Description

ARTICLE MANUFACTURED FROM POST-CONSUMER RESIN WITH FINISH SMOOTH SURFACE C7 7 frnn / 77Π7 / Β / YILI BACKGROUND OF THE INVENTION The environmental hazards caused by plastic waste are well-known. Large-scale societal efforts are underway to recycle and reuse plastic materials, commonly known as post-consumer recycled (PCR) resin. Efforts to reprocess and reintegrate PCR into usable consumer goods continue to expand. However, when molded articles are manufactured from post-consumer recycled polymer material, the molded articles have been found to have diminished physical properties. Extruded profile articles, in particular, require (1) a smooth surface to allow for uniform sealing and (2) the absence of spot defects that tend to decrease abuse performance. To date, efforts to mold PCR into extruded profile articles with a suitable smooth surface have been inadequate. The technique recognizes the need for polymer compositions that, when recycled, can produce articles with the same or better physical properties compared to articles produced from virgin polymer material. There is also a need for compositions Ref. 333433 polymeric materials that, when recycled, can produce molded articles with a smooth surface suitable for surface sealing and without spot defects. BRIEF DESCRIPTION OF THE INVENTION This description provides a process. In one embodiment, the process includes providing pellets of a ground material. The ground material is a post-consumer recycled multilayer film (PCR multilayer film) having at least three layers. The PCR multilayer film comprises (i) a polyethylene layer, (ii) a polyamide layer, and (iii) a coextrusion adhesive. The coextrusion adhesive comprises substantially linear ethylene polymer grafted with maleic anhydride (MAH-g-SLEP) having an Mw / Mn ratio of 1.5 to less than 3.5 and a melt index of 0.5 g / 10 min to less than 25 g / 10 min. The process includes extruding the pellets to form an extrudate, molding the extrudate, and forming, with the extrudate, a molded article having a surface. The surface of the molded article has a surface roughness value, Sa, of less than 1000 nm and a mean square roughness value, Sq, of less than 1400 nm. This description provides an article. In one embodiment, a molded article is provided that includes a body composed of an extruded post-consumer recycled multilayer film. The body includes polyethylene, polyamide, and a substantially linear ethylene polymer grafted with C7 / ΠΠΠ / 77Ω7 / Β / YILI maleic anhydride. The body has a surface. The surface of the body has a surface roughness value, Sa, less than 1000 nm and a root mean square roughness value, Sq, less than 1400 nm. BRIEF DESCRIPTION OF THE FIGURES Figure 1 is a scanning electron micrograph (SEM) of a film surface and a Sa-Sq surface roughness model of a comparative film sample. Figure 2 is a scanning electron micrograph (SEM) of the surface of a film and a Sa-Sq surface roughness model of inventive example 2 according to an embodiment of the present description. Figure 3 is a scanning electron micrograph (SEM) of the surface of a film and a Sa-Sq surface roughness model of inventive example 3 according to an embodiment of the present description. DETAILED DESCRIPTION OF THE INVENTION DEFINITIONS Any reference to the periodic table of the elements is made with respect to the one published by CRC Press, Inc., 1990-1991. Reference to a group of elements in this table is made according to the new notation for numbering groups. For the purposes of U.S. patent practice, the contents of any patent, patent application, or C7 / ΠΠΠ / 77Ω7 / Β / YΙΛΙ publication to which reference is made is incorporated by reference in its entirety (or its equivalent American version is so incorporated by reference) especially with regard to the description of definitions (insofar as they do not contradict any of the definitions specifically provided in this description) and general knowledge in the art. The numerical intervals described herein include all values ​​from the lower and upper limits inclusive. In the case of intervals containing explicit values ​​(e.g., 1 or 2, or 3 to 5, or 6, or 7), any subinterval between any two explicit values ​​is included (e.g., the interval 1-7 above includes the subintervals 1 to 2; 2 to 6; 5 to 7; 3 to 7; 5 to 6; etc.). Unless otherwise stated, implied from the context, or customary in the art, all parts and percentages are based on weight, and all testing methods are current as of the date of submission of this description. The term polymer blend or mixture, as used in this document, refers to a mixture of two or more polymers. Such a mixture may or may not be miscible (not phase-separated at the molecular level). The mixture may or may not exhibit phase separation. The mixture may or may not contain one or more domain configurations, as determined from transmission electron spectroscopy, light scattering, X-ray scattering, and other methods known in the art. The term composition refers to a mixture of materials comprising the composition, as well as reaction products and decomposition products formed from the composition materials. The expressions "comprising," "including," "having," and their derivatives are not intended to exclude the presence of any additional component, step, or process, whether specifically described or not. For the avoidance of doubt, all compositions claimed using the expression "comprising" may include any additive, adjuvant, or additional compound, whether polymeric or not, unless otherwise stated. Conversely, the expression "consisting essentially of" excludes from the scope of any subsequent recitation any other component, step, or process, except those not essential to operability. The expression "consisting of" excludes any component, step, or process that is not specifically defined or enumerated. The term "or," unless otherwise stated, refers to the members listed individually as well as in any combination. The use of the singular includes the use of the plural and vice versa. An ethylene-based polymer is a polymer containing more than 50 percent by weight (wt%) of polymerized ethylene monomer (based on the total amount of polymerizable monomers) and may optionally contain at least one comonomer. An ethylene-based polymer includes ethylene homopolymers and ethylene copolymers (i.e., ethylene-derived units and one or more comonomers). The terms ethylene-based polymer and polyethylene may be used interchangeably. Non-limiting examples of ethylene-based polymers (polyethylene) include low-density polyethylene (LDPE) and linear polyethylene.Non-limiting examples of linear polyethylene include linear low-density polyethylene (LLDPE), ultra-low-density polyethylene (ULDPE), very low-density polyethylene (VLDPE), multi-component ethylene-based copolymers (EPE), ethylene / α-olefin multiblock copolymers (also known as olefin block copolymers (OBCs)), substantially linear or linear plastomers / elastomers, and high-density polyethylene (HDPE). Generally, polyethylene can be produced in gas-phase fluidized bed reactors, liquid-phase suspension process reactors, or liquid-phase solution process reactors, using a heterogeneous catalytic system such as a Ziegler-Natta catalyst, or a homogeneous catalytic system comprising Group 4 transition metals and ligand structures such as metallocene, metal-centered non-metallocene heteroaryl, heterovalent aryloxy ether, phosphinimine, and others.Combinations of heterogeneous and / or homogeneous catalysts can also be used in single reactor or dual reactor configurations. High-density polyethylene (or HDPE) is an ethylene homopolymer or an ethylene / a-olefin copolymer with at least one C4-C10 α-olefin comonomer, or C4-C8 α-olefin comonomer and a density of 0.940 g / cc, or 0.945 g / cc, or 0.950 g / cc, 0.953 g / cc a 0.955 g / cc, or 0.960 g / cc, or 0.965 g / cc, or 0.970 g / cc, or 0.975 g / cc, or 0.980 g / cc. HDPE can be a monomodal copolymer or a multimodal copolymer. A monomodal ethylene copolymer is an ethylene / C4-C10 α-olefin copolymer that exhibits a single distinct peak on gel permeation chromatography (GPC), reflecting the molecular weight distribution. A multimodal ethylene copolymer is an ethylene / C4-C10 α-olefin copolymer that exhibits at least two distinct peaks on GPC, reflecting the molecular weight distribution. Multimodal includes copolymers with two peaks (bimodal) as well as copolymers with more than two peaks.Non-limiting examples of HDPE include DOW™ high-density polyethylene (HDPE) resins (available through The Dow Chemical Company), CONTINUUM™ bimodal polyethylene resins (available through The Dow Chemical Company), LUPOLEN™ (available through LyondellBasell), as well as HDPE products from Borealis, Ineos, and ExxonMobil. Low-density polyethylene (or LDPE) consists of an ethylene homopolymer or an ethylene / α-olefin copolymer comprising at least one C3-C10 α-olefin, having a density of 0.915 g / cc to less than 0.940 g / cc and containing long-chain branching with extensive molecular weight distribution (MWD). LDPE is typically produced by high-pressure free-radical polymerization (tubular reactor or autoclave with a free-radical initiator). Non-limiting examples of LDPE include MarFlex™ (Chevron Phillips), LUPOLEN™ (LyondellBasell), and LDPE products from Borealis, Ineos, ExxonMobil, and others. Linear low-density polyethylene (or LLDPE) is a linear ethylene / α-olefin copolymer containing a heterogeneous short-chain branching distribution comprising ethylene-derived units and units derived from at least one C3-C10 α-olefin comonomer. LLDPE is characterized by little, if any, long-chain branching, in contrast to conventional LDPE. LLDPE has a density of 0.910 g / cc to less than 0.940 g / cc. Non-limiting examples of LLDPE include TUFLIN™ linear low-density polyethylene resins (available through The Dow Chemical Company), DOWLEX™ polyethylene resins (available through The Dow Chemical Company), FINGERPRINT™ polyethylene resins (available through The Dow Chemical Company), and MARLEX™ polyethylene (available through Chevron Phillips). C7 / frnn / 77Ω7 / B / YILI An olefin-based polymer or polyolefin is a polymer that contains a majority amount, or more than 50% by weight, of polymerized olefin monomer, for example, ethylene or propylene (depending on the polymer's weight), and may optionally contain at least one comonomer. Non-limiting examples of olefin-based polymers include ethylene-based polymers and propylene-based polymers. A polymer is a polymeric compound prepared by the polymerization of monomers, whether of the same or different types. Therefore, the generic term polymer encompasses the term homopolymer (used to refer to polymers prepared from a single type of monomer, with the understanding that trace amounts of impurities may be incorporated into the polymer structure) and the term interpolymer. Trace amounts of impurities, such as catalyst residues, may be incorporated into and / or within the polymer. It also encompasses all forms of copolymer, such as random, block, etc. The terms ethylene / α-olefin polymer and propylene / α-olefin polymer are indicative of a copolymer, as described above, prepared from the polymerization of ethylene or propylene, respectively, and one or more additional polymerizable α-olefin monomers.It is important to note that, while polymers are often described as being made from one or more specific monomers, based on a specific monomer or type of monomer, containing a specific monomer content, or similar terms, in this context the term monomer refers to the polymerized residue of the specific monomer and not to the unpolymerized form. Generally, polymers herein are referred to as being based on units that are the polymerized form of a corresponding monomer. A propylene-based polymer is a polymer containing more than 50 percent by weight of polymerized propylene monomer (based on the total amount of polymerizable monomers) and may optionally contain at least one comonomer. The terms propylene-based polymer and polypropylene may be used interchangeably. As used herein, the term coextrusion adhesive is a film layer that serves to bond two film layers together; layers that would otherwise not adhere to each other, or would not adhere to each other with sufficient bond strength. Each of ultra-low-density polyethylene (or ULDPE) and very-low-density polyethylene (or VLDPE) is a linear ethylene / α-olefin copolymer containing a heterogeneous short-chain branching distribution comprising ethylene-derived units and units derived from at least one C3-C10 α-olefin comonomer. Each of ULDPE and VLDPE has a density of 0.885 g / cc to 0.915 g / cc. Non-limiting examples of ULDPE and VLDPE include ATTANE™ ultra-low-density polyethylene resins (available through The Dow Chemical Company) and FLEXOMER™ very-low-density polyethylene resins (available through The Dow Chemical Company). TEST METHODS Density is measured in accordance with ASTM D792, Method B. The result is reported in grams per cubic centimeter (g / cc). Differential scanning calorimetry (DSC) can be used to measure the melting, crystallization, and glass transition behavior of a polymer over a broad temperature range. For example, the TA Instruments Q1000 DSC, equipped with a refrigerated cooling system (RCS) and an autosampler, is used to perform this analysis. During testing, a nitrogen purge gas flow of 50 mL / min is used. Each sample is melt-pressed to form a thin film at approximately 175 °C; the molten sample is then cooled in air to room temperature (approximately 25 °C). A 3–10 mg, 6 mm diameter sample is extracted from the cooled polymer, weighed, placed in a lightweight aluminum pan (approximately 50 mg), and sealed. Analysis is then performed to determine its thermal properties. The thermal behavior of the sample is determined by increasing and decreasing the sample temperature in order to C7 / frnn / 77P7 / B / YILI to create a heat flow profile versus temperature. First, the sample is rapidly heated to 180 °C and held isothermally for 3 minutes to remove its thermal history. Then, the sample is cooled to -40 °C at a cooling rate of 10 °C / minute and held isothermally at -40 °C for 3 minutes. Next, the sample is heated to 180 °C (this is the second heating rise) at a heating rate of 10 °C / minute. The cooling and second heating curves are recorded. The cooling curve is analyzed by establishing baseline criteria from the start of crystallization down to -20 °C. The heating curve is analyzed by establishing baseline criteria from -20 °C to the end of melting. The determined values ​​are the extrapolated start of melting, Tm, and the extrapolated start of crystallization, Te.Heat of fusion (Hf) (in joules per gram), and the % of crystallinity calculated for polyethylene samples using the following equation:. % crystallinity = ((Hf) / 292 J / g) x 100 The heat of fusion (Hf) and peak melting temperature are reported from the second heating curve. The peak crystallization temperature is determined from the C7 / ΠΠΠ / 77Ω7 / Β / ΥΙΛΙ cooling curve. The melting point, Tm, is determined from the DSC heating curve by first plotting the initial value between the start and end of the melting transition. Then, a line tangent to the data on the low-temperature side of the melting peak is drawn. The location where this line intersects the initial value is the extrapolated start of melting (Tm). This is as described in Bernhard Wunderlich, "The Basis of Thermal Analysis," in Thermal Characterization of Polymeric Materials 92, 277–278 (Edith A. Turi ed., 2nd edition 1997). The crystallization temperature, Te, is determined from a DSC cooling curve as defined above, except that the tangent line is plotted on the high-temperature side of the crystallization peak. The location where this tangent intersects the initial value is the extrapolated start of crystallization (Te). The glass transition temperature, Tg, is determined from the DSC heating curve where half of the sample has reached the heat capacity of liquids, as described in Bernhard Wunderlich, "The Basis of Thermal Analysis," in Thermal Characterization of Polymeric Materials 92, 278–279 (Edith A. Turi ed., 2nd ed. 1997). Baselines are drawn from below and above the glass transition region and extrapolated across the Tg region. The temperature at which the sample's heat capacity is C7 J Ιτηη / Zζηζ / E / YΙΛΙ at the midpoint between these initial values ​​is the Tg. The melting index (MI) (12) is measured according to ASTM D1238 (190 °C / 2.16 kg) and the results are reported in grams per 10 minutes (g / 10 min) or decigrams per minute (dg / min). The melting index (110) is measured according to ASTM D1238 (190 °C / 10 kg), with the results reported in g / 10 min. The melting index ratio (110 / 12) is calculated according to ASTM D1238 at 190 °C by dividing the values ​​obtained at 10 kg and 2.16 kg. The strain at break is measured in accordance with ASTM D638 and the results are reported as a percentage (%). Surface roughness. The film samples are mounted with double-sided tape onto an aluminum sample holder to ensure they are flat. The film sample is analyzed using a Keyence VK X 200 confocal laser scanning microscope with a 50x objective lens (manufacturer specifications: Z resolution = 0.5 nm; spatial resolution (XY) = 120–130 nm; smallest detectable object = 8 nm; beam spot diameter with 50x lens = 590 nm). • A 3x3 mounting area is captured for roughness measurements. • The image is joined using a software package within Keyence's VK Analyzer package. • A Scanning Probe Image software package is used C7 / ΠΠΠ / 77Ω7 / Β / ΥΙΛΙ Processor (SPIP), available from Image Metrology A / S Denmark, for probe microscopy and optical profilometry analysis. • Once loaded into the SPIP software, the image tilt is corrected with a first-order polynomial. • A region of interest is defined through an inspection box to mitigate the influence of joining artifacts on the outer edges of the image. • The classic SPIP parameters Sa and Sq are calculated using the roughness and texture analysis toolbox according to Equation A and Equation B: Vl.Vl h Σ Σ Equation A: '·= C7 / frnn / ZZnZ / Ε / ΥΙΛΙ .Ul.Vl 5.= — V Tñuuvh* - 1 IL' - Equation B: -- • Two-dimensional (2D) images are exported after adding a 200 micrometer scale bar. • Three-dimensional (3D) images are also exported after adjusting the perspective of each sample to be approximately the same. The 3D images help visualize differences in surface roughness. This description provides a process. In one embodiment, the process includes providing pellets of a ground material. The ground material is a post-consumer recycled multilayer film (PCR multilayer film) having at least three layers. The PCR multilayer film comprises (i) a polyethylene layer, (ii) a polyamide layer, and (iii) a coextrusion adhesive. The coextrusion adhesive comprises substantially linear ethylene polymer grafted with maleic anhydride (MAH-g-SLEP) having an Mw / Mn ratio of 1.5 to less than 3.5 and a melt index of 0.5 g / 10 min to less than 25 g / 10 min. The process includes extruding the pellets to form an extrudate, molding the extrudate, and forming, with the extrudate, a molded article having a surface. The surface of the molded article has a surface roughness value, Sa, of less than 1000 nm and a mean square roughness value, Sq, of less than 1400 nm. The process includes providing pellets of a ground material. The ground material is a multilayer PCR film. A multilayer PCR film, as used herein, is a multilayer PCR film having at least three layers: (i) a polyethylene layer, (ii) a polyamide layer, and (iii) a coextruded adhesive. PCR is understood to include post-industrial recycled resin (PIR). The polyethylene layer of the PCR multilayer film is composed of one or more polyethylenes. The polyethylene can be an ethylene homopolymer or an ethylene / allefin copolymer. In one embodiment, the ethylene-based polymer is an ethylene / C3-C32 α-olefin copolymer. Non-limiting examples of ethylene / C3-C32 α-olefin copolymers include ethylene / propylene copolymer, ethylene / butene copolymer, ethylene / l-hexene copolymer, and ethylene / 1 C7 7 frnn / 77Ω7 / Β / ΥΙΛΙ octene. The ethylene / C3-Ci2 α-olefin copolymer may be an MDPE, LDPE, LLDPE, ULDPE, VLDPE, HDPE and combinations thereof. In a further embodiment, the ethylene-based polymer is an ethylene / Cy-Cs α-olefin copolymer. A polyamide, as used herein, is a polymer in which one or more amide linkages of Structure (1) occur along the molecular chain; Structure (1) is provided below. Structure (1) OH II I — C—N—. The polyamide layer of the PCR multilayer film is composed of a polyamide having Structure (1). Non-limiting examples of suitable polyamide include Nylon 6, Nylon 66, Nylon 11, or Nylon 12, and any combination thereof. In one embodiment, the polyamide has a Tm of 175 °C to less than 270 °C, or of 175 °C to less than 230 °C. The coextrusion adhesive of the PCR multilayer film is composed of substantially linear ethylene polymer grafted with maleic anhydride (MAH-g-SLEP) having an Mw / Mn ratio of 1.5 to less than 3.5 and a melt index of 0.3 g / 10 min to less than 25 g / 10 min. As used herein, a substantially linear ethylene-alpha-olefin copolymer (or SLEP) is an ethylene-based copolymer in which the comonomer is randomly distributed. C7 / RPR / 77Ω7 / B / YILI within a given copolymer molecule, and in which substantially all, or all, of the copolymer molecules have the same ethylene / comonomer ratio within that copolymer. The substantially linear ethylene copolymer is prepared by using a restricted geometry catalyst. Examples of restricted geometry catalysts, and their preparations, are also described in USP 5,272,236 and 5,278,272. Furthermore, a substantially linear ethylene copolymer is a homogeneously branched ethylene copolymer that has long-chain branches. These long-chain branches have the same comonomer distribution as the polymer backbone and can be approximately the same length as the backbone. "Substantially linear" typically refers to a polymer that is substituted, on average, with 0.01 to 3 long-chain branches per 1000 total carbons. The length of a long-chain branch is greater than the carbon length of a short-chain branch formed by the incorporation of a comonomer into the polymer backbone. In one embodiment, SLEP is replaced with from 0.01 long-chain branches per 1000 total carbons to 1 long-chain branch per 1000 total carbons, or 0.05 long-chain branches per 1000 total carbons to 1 long-chain branch per 1000 total carbons, or from 0.3 long-chain branches per 1000 total carbons to 1 long-chain branch per 1000 total carbons. Non-limiting commercial examples of substantially linear polymers include ENGAGE™ polymers and AFFINITY™ polymers (both available from The Dow Chemical Company). Substantially linear ethylene copolymers (SLEPs) are a unique class of homogeneously branched ethylene polymers. SLEPs are described in USP 5,272,236; 5,278,272; 6,054,544; 6,335,410; and 6,723,810; the full contents of each are incorporated herein by reference. SLEPs differ substantially from the well-known class of conventional homogeneously branched linear ethylene polymers described by Elston in USP 3,645,992 and are not in the same class as conventional heterogeneous Ziegler-Natta catalyst-polymerized linear ethylene polymers (e.g., ultra-low-density polyethylene (ULDPE), linear low-density polyethylene (LLDPE), or high-density polyethylene (HDPE) manufactured, for example, by the technique described by Anderson et al.)., in USP 4,076,698); nor are they in the same class as highly branched, high-pressure polyethylenes initiated by free radicals such as, for example, C7 / ΠΠΠ / 77Ω7 / Β / ΥΙΛΙ low-density polyethylene (LDPE), ethyleneacrylic acid copolymers (EAA) and ethylene vinyl acetate copolymers (EVA). A substantially linear ethylene polymer grafted with maleic anhydride, or MAH-g-SLEP, as used herein, is a SLEP with 0.05 wt% to 3 wt% maleic anhydride grafted onto the polymer backbone. The wt% is a function of the total weight of the MAH-g-SLEP. MAH-g-SLEP has one, some, or all of the following properties: (i) Mw / Mn of 1.5 to less than 3.5, or of 1.7 to 3.0, or of 2.0 to 2.7; and / or (ii) a melting index of 0.3 g / 10 min to less than 25 g / 10 min, or of 0.5 g / 10 min to 15 g / 10 min, or of 1.0 g / 10 min to 5 g / 10 min, or of 1.5 g / 10 min to 3.0 g / 10 min; and / or (iii) a density of 0.900 to 0.930 g / cc, or of 0.910 to 0.920 g / cc; (iii) a 110 / 12 of 6 to 10; and / or (iv) from 0.05 long chain branches / 1000 carbons to 1 long chain branch / 1000 carbons; and / or (v) from 0.05 wt% to 3 wt%, or from 0.5 wt% to 1.5 wt%, or from 0.8 wt% to 1.3 wt% of maleic anhydride (based on the total weight of MAH-g-SLEP). MAH-g-SLEP is described in U.S. Patent No. 5,346,963, the full content of which is incorporated herein as C7 / frnn / 77Ω7 / Β / ΥΙΛΙ reference. In one embodiment, the PCR multilayer film includes a layered structure in which the coextrusion adhesive makes direct contact with the polyamide layer. The expression "makes direct contact with," as used herein, refers to a layer configuration in which a first layer is located immediately adjacent to a second layer and there are no intervening layers, or no intermediate structures, present between the first and second layers. In one embodiment, the PCR multilayer film is a five-layer film with the structure PE / adhesive / PA / adhesive / PE, where PE is a polyethylene layer, adhesive is a coextruded adhesive, and PA is a polyamide layer. The coextruded adhesive makes direct contact with the polyamide layer. The present process includes providing pellets of a ground material, where the ground material is the PCR multilayer film. The term ground material, as used herein, includes particles of post-consumer recycled resin, where the post-consumer recycled resin is the PCR multilayer film as described earlier in this document. The term post-consumer recycled resin (or PCR) is a polymeric material that has been previously used as consumer or industrial packaging. In other words, PCR is waste plastic. PCR is typically obtained C7 / RPRP / 77Ω7 / B / YILI from recycling programs and recycling plants. PCR generally requires additional cleaning and processing before it can be reintroduced into a manufacturing line. PCR is the PCR multilayer film after it has completed its first use; that is, after it has fulfilled its primary purpose. PCR is understood to include post-industrial recycled resin (PIR). In one embodiment, the PCR multilayer film is a waste barrier film that was used to contain, or otherwise store, consumer edible oil. PCR is different from virgin polymer material. Because PCR has undergone an initial heat and molding process, it is not a virgin polymer material. A virgin polymer material is a polymer material that has not undergone, or otherwise been subjected to, a heat or molding process. The physical, chemical, and flow properties of PCR resin differ from those of virgin polymer resin. In one modality, the process includes flaking the multilayer PCR film to form flakes. The process further includes densifying the flakes to form pellets of the ground material. In one embodiment, a film containing MAH-g-SLEP is fed into a shredder equipped with cutting blades capable of converting the film into individual flakes of C7 / PRP / 77Ω7 / E / YILI nominally less than 3.0 centimeters in diagonal length. These flakes are transferred and metered through various conventional systems to the feed zone of an extruder. The extruder is designed to densify and melt the flakes to form a pool of molten polymer. This polymer pool is pressurized and pushed out of the extruder through a die where the polymer can be converted into a solid pellet. The pellets are collected, and any contact water is removed from the process. Optimizations of the densification process would include the use of a device to assist in pushing the flakes into the feed zone of an extruder. Some extruders are designed with a vent port to allow moisture or volatile elements present in the polymer stream to escape.The conversion of molten polymer into pellets can be achieved by cutting strands of the polymer or by using a submerged pelleting unit. In all cases, the pellets must be solid and without voids. In an additional embodiment, the initial film can be obtained from a snip roll produced during the initial production of the film or from the film after it has been used for its intended purpose. The process involves extruding pellets of ground material (e.g., pellets from the PCR multilayer film) to form an extrudate. The term extrude C7 / ΠΠΠ / 77Ω7 / Β / YILI Extrusion is a process in which a polymer is fed into an extruder and continuously propelled along a screw through regions of high temperature and pressure where the polymer melts and compacts, and is finally forced through a die. The extruder can be a single-screw extruder, a multi-screw extruder, a disc extruder, or a piston extruder. The process involves molding the extrudate (formed from molten pellets of ground material) to create an article. The term molding, as used here, refers to a process where a polymer is melted and formed into an extrudate. The extrudate is then fed into a mold, which is the inverse of a desired shape, to form an article (or part) with a desired shape and size. Molding can be pressure-assisted or non-pressure. The process includes the formation of a molded article that has a surface. The surface has a surface roughness value, Sa, of less than 1000 nm and a root mean square roughness value, Sq, of less than 1400 nm. In one embodiment, the process includes profile molding the extrudate (formed from molten pellets of the ground material) and forming a profiled article. The term profile molding, as used herein, is a process in which a polymeric material is melted and transformed into an extrudate, and the extrudate is subsequently forced through an extrusion die, where the extrudate takes the shape of the extrusion die, resulting in a profile. Upon exiting the extrusion die, the profile takes its final shape and is simultaneously cooled. The cooled profile is then cut, thus forming a profiled article. Profile articles have a continuous cross-section, such as pipes, decorative moldings, and exterior automotive trim. Profile molding is advantageous for producing continuous, uniform thermoplastic articles with complex cross-sections. Non-limiting examples of profile articles include wire and cable sheathing, flexible tubing, weatherstripping, plastic lumber, and decorative moldings. In one instance, the profile article has a thickness greater than 0.254 millimeters (10 thousandths of an inch). A thickness of 0.254 millimeters (10 thousandths of an inch) is generally considered the upper limit for an extruded film. In other words, a profile article with a thickness greater than 0.254 millimeters is not a film and excludes extruded films. In one embodiment, the process involves injection molding the extrudate (formed from molten pellets of the ground material) to form an injection-molded article. The term injection molding, as used herein, is a process by which a polymeric material is melted and injected at high pressure into a mold, where the mold is the inverse of the desired shape, to form an article of the desired shape and size. The mold may be made of metal, such as steel or aluminum. In one embodiment, the process involves blow-molding the extrudate (formed from molten pellets of ground material) to create a blow-molded article. The term blow molding, as used herein, refers to a process that includes placing an extrudate in the center of a mold, blowing the polymer against the mold walls with a blow mandrel, and solidifying the product by cooling. Blow molding can be used to manufacture hollow plastic containers. In one embodiment, the process includes providing pellets of the ground material having from (i) 82 wt% to 89.5 wt% polyethylene, from 10 wt% to 15 wt% polyamide, and from 0.5 wt% to 3.0 wt% MAH-g-SLEP. The process includes injection molding the extrudate and forming an injection-molded article having a surface. The surface has a Sa value of 400 nm to 900 nm and an Sq value of 500 nm to 1200 nm. In one embodiment, the process includes mixing 1 wt% to 70 wt% of ground material pellets with 99 wt% to 30 wt% of virgin polyethylene. The process includes extruding the pellets and virgin polyethylene to form a mixture extrudate and molding the extrudate to form a molded article. The molded article has a surface. The surface has a surface roughness value, Sa, of less than 1000 nm and a root mean square roughness value, Sq, of less than 1400 nm. This description provides for a molded article. In one embodiment, the molded article includes a body composed of an extruded post-consumer recycled multilayer film. The body is composed of (i) polyethylene, (ii) polyamide, and (iii) a substantially linear ethylene polymer grafted with maleic anhydride. The body has a surface. The surface has a surface roughness value, Sa, of less than 1000 nm and a root mean square roughness value, Sq, of less than 1400 nm. In one embodiment, the body of the molded article is formed from an extruded post-consumer recycled multilayer film and is composed of (i) 82% by weight to 89.5% by weight of polyethylene; (ii) 10 wt% to 15 wt% polyamide; and (iii) 0.5 wt% to 3.0 wt% substantially linear ethylene polymer grafted with maleic anhydride MAH-g-SLEP. The body has a surface. The surface has a surface roughness value, Sa, from 400 nm to 900 nm and an Sq value from 500 nm to 1200 nm. By way of example, and not as a limitation, the following will be described in C7 / frnn / 77Ω7 / Β / YILI details some modalities of the present description in the following Examples. EXAMPLES Table 1 below provides a list of the materials used in the Examples. Table 1: Materials C7! ΠΠΠ / 77Ω7 / Β / ΥΙΛΙ Resin Propiedades Fuente LLDPE ethylene / octeno copolymer ELITE 5401G I2 -10 g / 10 min d -0.918 g / cc Dow Inc. LLDPE ethylene / octeno copolymer ELITE 5400G 12-1.0 g / 10 min d -0.916 g / cc Dow Inc. MAH-g-SLEP Copolymer of substantially linear ethylene / octeno injected with maleic anhydride (MAH-g-SLEPI) I2-3.0 g / 10 min d -0.912 g / cc Mw / Mn - 2.7 MAH -1.1 % by weight Dow Inc. LLDPE injected with maleic anhydride (heterogeneous copolymer, catalyzed with Ziegler-Natta) (OREVAC 825) I2-3.0 g / 10 min d -0.913 g / cc MAH - 0.9 % en weight Vicat 99°Ca10N Orevac 825, Arkema Poliamida Nylon 6 Nylon B33L 12 2.19-3.41 g / 10 min d 1.12-1.15 g / cc BASF LLDPE Copolymer of ethylene / butene CEFOR1211P 12-1.0 g / 10 min d -0.918 g / cc Dow Inc. Anti-slip LDPE LDPE310E I2-0.75 g / 10 min d -0.916 g / cc Dow Inc. Anti-slip LDPE LDPE312E I2-0.75 g / 10 min d -0.918 g / cc Dow Inc. cz / frnn / zznz / E / YiAi d = density (g / cc), 12 = melt index (g / 10 min), % by weight based on the total weight of polyethylene grafted with MAH A. Manufacturing of multilayer films Three five-layer coextruded films were manufactured on a Tab Tech five-layer extruder, with layer thicknesses controlled by the individual extruder outlets connected to the five layers. All extruders used a linear zone temperature profile starting at 100 °C and increasing to 325 °C at the die. The die temperature was controlled at 325 °C. Each multilayer film had the following layer structure: PE / adhesive / PA / adhesive / PE. The material composition for the polyethylene layer (PE sealing layer), the polyamide layer (PA barrier layer), and the second polyethylene layer (PE outer layer) for each of the three films was kept constant. The coextrusion adhesive material composition was varied to evaluate recycling performance. The coextrusion adhesive compositions evaluated included Orevac 825 and MAH-gSLEP1.Table 2 below provides the structure / composition of five-layer films of. PE / adhesive / PA / adhesive / PE that have a thickness of 72 µm. Table 2 C7 / frnn / 77Ω7 / B / YILI % Vol Film 1 Film 2 Film 3 Polyethylene layer (sealing layer) Inner 80% ELITE 5401G + 20% LDPE 312E 80% ELITE 5401G + 20% LDPE 312E 80% ELITE 5401G + 20% LDPE 312E Coextrusion adhesive 7.5 15% OREVAC 825+ 85% CEFOR 1211P 15% MAH-g- SLEP1 + 85% CEFOR 1211P 25% MAH-g- SLEP1 + 75% CEFOR 1211P Polyamide layer (barrier layer) Nylon B33L Nylon B33L Nylon B33L Adhesive 7.5 15% OREVAC 825+ 85% CEFOR 1211P 15% MAH-g- SLEP1 + 85% CEFOR 1211P 25% MAH-g- SLEP1 + 75% CEFOR 1211P Polyethylene layer (outer layer) 80% ELITE 5400G + 20% LDPE 310E 80% ELITE 5400G + 20% LDPE 310E 80% ELITE 5400G + 20% LDPE 310E Corresponding % of adhesive resin in the full film formulation 15% 2.14% OREVAC 825 2.14% MAH-g SLEP1 3.5% MAH-g- SLEP1 B. Multilayer film granulation Each multilayer film from Table 2 above was ground into granular form. The pellets averaged 30 pellets per gram. Each multilayer film from Table 2 was fed into a high-speed cutter, which flaked the film, converting it into a spongy flake material. This spongy flake material was then fed into a twin-screw extruder, which densified the flakes to form PCR multilayer film pellets. The pellets were 3–4 mm in length (longest dimension). The pellets of ground PCR material are fed into an Arburg machine (at 220 °C) to produce injection-molded extrusion plates measuring 10 mm x 10 mm x 2 mm thick. Each plate was mounted with double-sided tape onto an aluminum sample holder to ensure the samples lay flat. Each sample was analyzed using a Keyence VK X 200 confocal laser scanning microscope with a 50x objective lens (manufacturer specifications: Z resolution = 0.5 nm; spatial resolution (XY) = 120–130 nm; smallest detectable object = 8 nm; beam spot diameter with 50x lens = 590 nm). A 3x3 mm mount image is captured to provide a suitable area for surface roughness measurements. The image is stitched using a software package within Keyence's VK Analyzer suite. The SPIP software package is used for probe microscopy and optical profilometry analysis. Once loaded into the SPIP software, the image tilt is corrected using a first-order polynomial. A region of interest is defined using an inspection box to mitigate the influence of stitching artifacts at the outer edges of the image. 2D images are exported after adding a 200-micrometer scale bar. 3D images are also exported after adjusting the perspective of each sample to be approximately equal. The 3D images help visualize differences in surface roughness. Table 3 below provides the surface roughness values, Sa and Sq, for the plates formed from grinding Film 1, Film 2, and Film 3 from Table 2. cz / πηη / ζζωζ / β / υιλι Table 3: Surface roughness of PCR multilayer film plates PCR Film structure by layer Film composition PCR* Layer thickness (µm) % of film volume Amount of MAHg-PE in PCR + Amount of PA in PCR + MAH-gPE / PA Injection molded plate area, nm Injection molded plate area, nm CS1 PE layer (sealing) 80% Elite 5401G + 20% LDPE 312E 28 38.9 Coextrusion adhesive 15% Orevac 825 + 85% 1MI CEFOR 1211P LLDPE 4 5.6 0.83 PA layer (barrier) - 100% Nylon B33L 8 11.1 12.7 Co-extrusion adhesive 15% Orevac 825 + 85% 1MI CEFOR 1211P LLDPE 4 5.6 0.83 PE layer (exterior) 80% Elite 5400G + 20% LDPE 310E 28 38.9 Total 1.67 12.7 0.13 1440 1880 IE2 PE layer (sealing) 80% Elite 5401G + 20% LDPE 312E 28 38.9 Co-extrusion adhesive 15% MAH-g-SLEP1 + 85% 1MI CEFOR 1211P 4 5.6 0.83 PA layer (barrier) 100% Nylon B33L 8 11.1 12.7 Coextrusion adhesive 15% MAH-g-SLEP1 + 85% 1MI CEFOR 1211P 4 5.6 0.83 PE layer (outer) 80% Elite 5400G + 20% LDPE 310E 28 38.9 Total 1.67 12.7 0.13 830 1130 Improvement over CS1 42% 40% IE3 PE layer (sealing) 80% Elite 5401G + 20% LDPE 312E 28 38.9 Coextrusion adhesive 25% MAH-g-SLEP1 + 75% 1MI CEFOR 1211P 4 5.6 1.39 PA layer (barrier) 100% Nylon B33L 8 11.1 12.7 Coextrusion adhesive MAH-g-SLEP1 + 75% 1MI C4 LLDPE 4 5.6 1.39 PE layer (outer) 80% Elite 5400G + 20% LDPE 310E 28 38.9 Total 2.78 12.7 0.22 430 530 Improvement over CS1 70% 72% *% by weight based on the total weight of the film layer, + % by weight based on the total weight of the PCR material CS = Comparative sample; IE = Example of the invention Table 3 shows that IE2 and IE3 plates formed from milled material with a coextrusion adhesive containing MAH-g-SLEPl exhibit an improved smooth surface compared to CS1 plate formed from milled material with a coextrusion adhesive that is a Ziegler-Natta catalyzed polymer grafted with MAH (Orevac 825). CS1 in Table 3 has an Sa value of 1440 nm compared to the respective Sa values ​​of IE2 and IE3 of 830 nm and 430 nm. CS1 in Table 3 has an Sq value of 1830 nm compared to the respective Sq values ​​of IE2 and IE3 of 1103 nm and 530 nm. At similar levels of Orevac 825 (CSl-2.14 wt., Ziegler-Natta catalyzed MAH-g-polymer) versus MAH-gSLEP1 (IE2-2.14 wt. MAH-g-SLEPl), the PCR resin milled with MAH-g-SLEPl exhibits a smoother surface finish: CS1 Sa / Sq 1440 / 1880 nm and IE2 Sa / Sq 830 / 1130 nm. As the amount of MAH-g-SLEPl increases (IE3-3.5 wt. MAH-g-SLEPl), the surface becomes even smoother: IE3 Sa / Sq 430 / 530 nm. It is specifically intended that the present description not be limited to the forms and illustrations contained herein, but include modified forms of those forms that include parts of the forms and combinations of elements of different forms that are within the scope of the following claims. It is hereby stated that, as of this date, the best method known to the applicant for putting the aforementioned invention into practice is the one that is clear from the present description of the invention.

Claims

1. A process, characterized in that it comprises: providing pellets of a ground material, wherein the ground material is a post-consumer recycled multilayer film (PCR multilayer film) having at least three layers of (i) a polyethylene layer, (ii) a polyamide layer and (iii) a coextrusion adhesive, the coextrusion adhesive being composed of substantially linear ethylene polymer grafted with maleic anhydride (MAH-g-SLEP) having Mw / Mn from 1.5 to less than 3.5 and a melt index from 0.3 g / 10 min to less than 25 g / 10 min, the ground material comprising from 82 wt% to 89.5 wt% polyethylene, from 10 wt% to 15 wt% polyamide, and from 0.5 wt% to 3.0% by weight of MAH-g-SLEP; extrude the pellets to form an extrudate; mold the extrudate; and form, with the extrudate, a molded article having a surface, wherein the surface has a surface roughness value, Sa, of less than 1000 nm and a mean square roughness value, Sq, of less than 1400 nm.

2. The process according to claim 1, characterized in that it comprises: flaking, prior to feeding, the PCR multilayer film to form flakes of the PCR multilayer film; and densifying the flakes to form pellets of the ground material.

3. The process according to any of claims 1-2, characterized in that it comprises injection molding the extrudate; and forming an injection-molded article having a surface, wherein the surface has a Sa value of 400 nm to 900 nm and an Sq value of 500 nm to 1200 nm.

4. The process according to any of claims 1-3, characterized in that it comprises mixing from 1% by weight to 70% by weight of the pellets of the ground material with from 99% by weight to 30% by weight of a virgin polyethylene; extruding the pellets and the virgin polyethylene to form a mixture extrudate; molding the mixture extrudate; and forming a molded article.

5. A molded article, characterized in that it comprises: a body composed of an extruded post-consumer recycled multilayer film, wherein the body comprises: polyethylene; C7 / RPR / 77Ω7 / B / YILI polyamide; and substantially linear ethylene polymer grafted with maleic anhydride; wherein the body has a surface, wherein the surface has a surface roughness value, Sa, of less than 1000 nm and a mean square roughness value, Sq, of less than 1400 nm.

6. The molded article according to claim 5, characterized in that it comprises: from 82 wt% to 89.5 wt% polyethylene; from 10 wt% to 15 wt% polyamide; and from 0.5 wt% to 3.0 wt% substantially linear ethylene polymer grafted with maleic anhydride MAH-gSLEP; wherein the body has a surface, wherein the surface has a surface roughness value, Sa, from 400 nm to 900 nm and a mean square roughness value, Sq, from 500 nm to 1200 nm.

7. The process according to claim 1, characterized in that the extrusion comprises melting, in an extruder, pellets of the ground material; and forcing the molten ground material through a die.