Polymer recyclate blends

Abstract

Provided are compatibilized blends of and processes for blending incompatible thermoplastic polymers, wherein at least one of the thermoplastic polymers is a polymer recyclate comprising a contaminant. A blend of incompatible thermoplastic polymers is compounded with a compatibilizer comprising first and second thermoplastic polymers, each grafted with one or more functional groups. The first and second thermoplastic polymers of the compatibilizer are each compatible with one component of the blend of incompatible thermoplastic polymers. The one or more functional groups of the compatibilizer react with the contaminant during compounding to produce a compatibilized blend of incompatible polymers.

Description

POLYMER REC YCLATE BLENDSFIELD OF THE INVENTION

[0001] The present disclosure relates to compatibilized blends of incompatible polymers, wherein at least one of the blend components is a polymer recy elate.BACKGROUND OF THE INVENTION

[0002] Plastic recycling requires sorting through and separating plastic waste by type into postconsumer recycled (PCR) resins. However, this process is not always 100% effective, resulting in a PCR resin that contains one or more types of unwanted plastics and / or cellulose fibers (e.g., from labels) being mixed in with the desired plastic. Additionally, limited availability of PCR resins may create a need for blending PCR resins. Both of these scenarios present the possibility of PCR polymer compositions comprising incompatible polymers. Incompatible polymer blends occur when the constituent polymers are immiscible, meaning they do not dissolve in each other and instead form distinct phases within the blend. This can result in a material with poor mechanical properties, reduced clarity, and limited processing options. Such blends include, but not limited to, blends of polyethylene and polypropylene. The quality issues associated with such polymer blends are exacerbated when one or both of the polymers in the blend are PCR resins containing contaminants such as nylon and / or paper.

[0003] It would be desirable to improve the compatibility between the polymers present in such blends to improve their mechanical and / or optical properties, thereby improving their utility in a broader spectrum of end use applications in the short term. In the long term, such compatibilization would provide increased utilization and consumption of PCR resins.

[0004] There is a need to provide improved compositions and processes using recycled polymers to produce products having a useful combination of properties that are competitive with or even beter than products and processes using only virgin polymer compositions. Ideally, such products could be implemented with commonly used equipment and familiar techniques to produce a wide variety of products.SUMMARY OF THE INVENTION

[0005] The present disclosure relates to improved blends of incompatible polymers and methods for making such improved blends. In some embodiments, a compatibilized blend of incompatible polymers comprises a mixture of a first thermoplastic polymer and a second thermoplastic polymer. The first and second thermoplastic polymers are incompatible. The first thermoplastic polymer comprises a first contaminant in an amount in the range of from 0 to 10 wt%, wherein wt% is based on the weight of the first thermoplastic polymer. The secondthermoplastic polymer comprises a second contaminant in an amount in the range of from 0 to 10 wt%, wherein wt% is based on the weight of the second thermoplastic polymer.

[0006] The mixture further comprises a compatibilizer. The compatibilizer comprises a third thermoplastic polymer grafted with one or more functional groups, wherein the third thermoplastic polymer is compatible with the first thermoplastic polymer, and a fourth thermoplastic polymer grafted with one or more functional groups wherein the fourth thermoplastic polymer is compatible with the second thermoplastic polymer. The first thermoplastic polymer comprises greater than 0 wt% of the first contaminant and / or the second thermoplastic polymer comprises greater than 0 wt% of the second contaminant. The mixture is subjected to compounding conditions sufficient to promote a reaction between the one or more functional groups and the first contaminant and / or the second contaminant to form a polymer product comprising a compatibilized blend of the first thermoplastic polymer and the second thermoplastic polymer.

[0007] In some embodiments, a method for compatibilizing a polymer blend comprises combining a first thermoplastic polymer, a second thermoplastic polymer, and a compatibilizer to form a mixture. The first thermoplastic polymer and / or the second thermoplastic polymer each comprise a contaminant in an amount in the range of from 0 to 10 wt%, wherein weight percentages are based on the weight of the first thermoplastic polymer and the second thermoplastic polymer, respectively. The second thermoplastic polymer is incompatible with the first thermoplastic polymer. The compatibilizer comprises a third thermoplastic polymer, grafted with one or more functional groups, and a fourth thermoplastic polymer, grafted with one or more functional groups. The third thermoplastic polymer is compatible with the first thermoplastic polymer, and the fourth thermoplastic polymer is compatible with the second thermoplastic polymer.

[0008] The mrxture is subjected to compounding conditions sufficient to promote a reaction between the one or more functional groups and the contaminant to form a polymer product comprising a compatibilized blend of the first thermoplastic polymer and the second thermoplastic polymer.

[0009] The present disclosure relates to a method for producing multilayer films, the method comprising providing a polymer recy elate, comprising a first low polarity polymer and a first high polarity polymer, the first high polarity polymer comprising a first polar comonomer. The method further comprises providing a compatibilizer, comprising a second low polarity polymer grafted with one or more functional groups. The polymer recy elate and the compatibilizer are mixed under compounding conditions sufficient to form a compatibilized polymer recyclate, wherein the compatibilized polymer recyclate has a dispersed phase of domains of the first high polarity polymer in a matrix phase of the first low polarity polymer. A third low polarity polymer, a second high polarity polymer, and the compatibilized polymer recyclate are coextruded to form amultilayer film comprising: i) a first layer, comprising the third low polarity polymer; 11) a second layer, comprising the second high polarity polymer; and iii) a tie layer, disposed between the first layer and the second layer.

[0010] The foregoing has outlined rather broadly the features and technical advantages of the present invention in order that the detailed description of the invention that follows may be better understood. Additional features and advantages of the invention will be described hereinafter, which form the subject matter of the claims of the invention. It should be appreciated by those skilled in the art that the conception and specific embodiments disclosed may be readily utilized as a basis for modifying or designing other film structures and / or processes for carrying out the same purposes of the present invention. It should also be realized by those skilled in the art that such equivalent constructions do not depart from the spirit and scope of the invention as set forth in the appended claims. The novel features which are believed to be characteristic of the invention, both as to its structure and method of manufacture, together with further objects and advantages will be better understood from the following description.DETAILED DESCRIPTION OF THE INVENTION

[0011] Illustrative embodiments of the subject matter claimed below will now be disclosed. In the interest of clarity, some features of some actual implementations may not be described in this specification. It will be appreciated that in the development of any such actual embodiments, numerous implementation-specific decisions must be made to achieve the developer’s specific goals, such as compliance with system-related and business-related constraints, which will vary from one implementation to another. Moreover, it will be appreciated that such a development effort, even if complex and time-consuming, would be a routine undertaking for those of ordinary skill in the art having the benefit of this disclosure.

[0012] The words and phrases used herein should be understood and interpreted to have a meaning consistent with the understanding of those words and phrases by those skilled in the relevant art. No special definition of a term or phrase, i.e., a definition that is different from the ordinary and customary meaning as understood by those skilled in the art, is intended to be implied by consistent usage of the term or phrase herein. To the extent that a term or phrase is intended to have a special meaning, i.e., a meaning other than the broadest meaning understood by skilled artisans, such a special or clarifying definition will be expressly set forth in the specification in a definitional manner that provides the special or clarifying definition for the term or phrase. It must also be noted that, as used in the specification and the appended claims, the singular forms "a," "an," and "the" include plural references unless otherwise specified.

[0013] For example, the following discussion contains a non-exhaustive list of definitions of several specific terms used in this disclosure (other terms may be defined or clarified in adefinitional manner elsewhere herein). These definitions are intended to clanfy the meanings of the terms used herein. It is believed that the terms are used in a manner consistent with their ordinary meaning, but the definitions are nonetheless specified here for clarity.Definitions

[0014] As used herein, “compatibility” means the capability of the individual component substances in an immiscible polymer blend to exhibit mterfacial adhesion, in which interfaces between phases or components are maintained by intermolecular forces, chain entanglements, or both, across the interfaces — i.e., holding together of two bodies by interfacial forces or mechanical interlocking on a scale of micrometers or less. Further discussion of miscibility can be found in D. W. Fox and R. B. Allen, ‘Compatibility’, Encyclopedia of Polymer Science and Engineering, 2nd Ed., J. T. Kroschwitz, ed., Wiley Tnterscience, New York, 1985, Vol. 3, p. 784. Work, W. J., Hone, K., Hess, M., & UK, R. S. (2004). Definitions of Terms Related to Polymer Blends, Composites and Multiphase Polymeric Materials, Pure and Applied Chemistry76 / 11, the substance of which is fully incorporated herein by reference.

[0015] As used herein, “compounding conditions” means temperature, pressure, and shear force conditions implemented in an extruder to provide intimate mixing of two or more polymers and optionally additives to produce a substantially homogeneous polymer product. The compounding conditions will be such that the specific energy from the compounder from shear and / or added heat are sufficient to melt the polymer components and homogenize them.

[0016] As used herein, “HDPE” means ethylene homopolymers and ethylene copolymers produced in a suspension, solution, slurry, or gas phase polymerization process and having a density in the range of 0.940 g / cm3to 0.970 g / cm3.

[0017] As used herein, “hPP” means a heterophasic propylene polymer materials consisting essentially of by weight, (i) 99-55% of a polymeric material selected from the group consisting of a propylene homopolymer having an isotactic index greater than 90, and a crystalline copolymer of propylene and an alpha-olefin of the formula CH2 =CHR, where R is H or a 2-6 carbon linear or branched alkyl group, having an isotactic index of at least 80, the alpha-olefin being less than 10% of the copolymer, and (11) 1-45% of an elastomeric olefin polymer of propylene and an olefinic material selected from the group consisting of alpha-olefins of the formula CH2=CHR, where R is H or a 2-6 carbon linear or branched alkyl group, the alpha-olefin being 50-70% of the elastomeric polymer.

[0018] As used herein, “iPP” means a propylene homopolymers having an isotactic index of at least 90.

[0019] As used herein, “EDPE” means ethylene homopolymers and / or ethylene copolymers produced in a high pressure free radical polymerization and having a density in the range of 0.910 g / cm3to 0.940 g / cm3.

[0020] As used herein, “LLDPE” means ethylene copolymers produced in a suspension, solution, slurry, or gas phase polymerization process and having a density in the range of 0.910 g / cm3to 0.940 g / cm3.

[0021] As used herein, “MDPE” means ethylene copolymers produced in a suspension, solution, slurry, or gas phase polymerization process and having a density in the range of 0.925 g / cm3to 0.940 g / cm3.

[0022] As used herein, “miscibility,” means the degree to which two polymers will mix to form a homogeneous polymer blends. Miscibility is the capability of a mixture to form a single phase over certain ranges of temperature, pressure, and composition. Whether or not a single phase exists depends on the chemical structure, molar mass distribution, and molecular architecture of the components present. A single phase in a mixture may be confirmed by light scattering, x-ray scattering, and / or neutron scattering. For a two-component mixture, a necessary and sufficient condition for stable or metastable equilibrium of a homogeneous, single-phase is:wherein AmixG is the Gibbs energy of mixing per unit volume, and the composition, where <D is usually taken as the volume fraction of one of the component substances. The system is unstable if the above second derivative is negative. The borderline (spinodal) between (meta)stable and unstable states is defined by the above second derivative equaling zero. Further discussion of miscibility can be found in J.M.G. Cowie, ‘Miscibility’, Encyclopedia of Polymer Science and Engineering, 2nd Ed., J.I. Kroschwitz, ed., Wiley Interscience, New York, 1985, Supplement, p. 455-480, and Work, W. J., Horie, K., Hess, M„ & UK, R. S. (2004), Definitions of Terms Related to Polymer Blends, Composites and Multiphase Polymeric Materials, Pure and Applied Chemistry 76 / 11, the substance of which is fully incorporated herein by reference.

[0023] As used herein, “olefin,” and alternatively referred to as “alkene,” is a linear, branched, or cyclic compound of carbon and hydrogen having at least one double bond.

[0024] As used herein, “PE” means polyethylene and includes any or all of EDPE, EEDPE, and HDPE.

[0025] As used herein, “polar polymer,” means a polymer or copolymer comprising units derived from a polar monomer. The term "polar polymer," as used herein, refers to polymerformed from at least one monomer that comprises at least one heteroatom. Some examples of heteroatoms include O, N, P and S.

[0026] As used herein, “polymer recy elate,” means post-consumer recycled (“PCR”) polymer and / or post-industrial recycled (“PIR”) polymer. Polymer recyclate is derived from an end product that has completed its life cycle as a consumer item and would otherwise be disposed of as waste (e.g., a polyethylene water bottle) or from plastic scrap that is generated as waste from an industrial process. Polymer recyclates herein are a mixture of a first low polarity polymer component and a high polarity polymer component comprising at least one polar monomer, such as produced by melting and mixing a barrier film having at least one layer of a first low polarity polymer component and at least on layer of a high polarity polymer component comprising at least one polar monomer.

[0027] As used herein, “PP” means polypropylene and includes any or all of iPP, RCP, and hPP.

[0028] As used herein, “processability” refers to how well a polymer composition can be formed into a cast of blown film of commercial quality or molded by injection or compression molding into a molded article of commercial quality at commercially acceptable rates using the equipment and conditions.

[0029] As used herein, “RCP” means random copolymers of propylene and ethylene or butylene, or random terpolymers of propylene, ethylene, and butylene, wherein the maximum ethylene content, or ethylene plus butylene content, is 10% by weight, having an isotactic index of at least 80.

[0030] It is noted that in this disclosure and particularly in the claims and / or paragraphs, terms such as “comprises”, “comprised”, “comprising” and the like can have the meaning attributed to it in U.S. patent law; e g., they can mean “includes”, “included”, “including”, and the like; and that terms such as “consisting essentially of’ and “consists essentially of’ have the meaning ascribed to them in U. S. patent law, e.g., they allow for elements not explicitly recited, but exclude elements that are found in the prior art or that affect a basic or novel characteristic of the disclosure. Incompatible Polymer Blend

[0031] In some embodiments, a compatibilized blend of incompatible polymers comprises a mixture of a first thermoplastic polymer and a second thermoplastic polymer. The main reasons for the incompatibility of polymer blends are differences in their chemical structure, molecular weight, and polarity. Polymer chains with different chemical structures are unable to intermingle with each other because of differences in their molecular size and shape. The difference in molecular weight also affects the compatibility of polymer blends, as the higher molecular weightpolymer tends to form a continuous phase, whereas the lower molecular weight polymer forms a dispersed phase.

[0032] Incompatible polymers are polymer that are not miscible with each other or have limited miscibility with each other such that a blend of the incompatible thermoplastic polymers has one or more of poorer processability, mechanical properties, and / or optical properties. Relevant mechanical properties include, but are not limited to, structural integrity, tensile properties, tear strength, puncture resistance, heat resistance, heat sealability, and / or abrasion resistance. Relevant optical properties include, but are not limited to haze, clarity, and gloss.

[0033] In some embodiments, the first thermoplastic polymer and / or the second thermoplastic polymer are each independently selected from the group consisting of: polyethylene, polypropylene, polyvinyl chloride, polystyrene, acrylonitrile butadiene styrene, fluoropolymers, ethylene vinyl acetate, thermoplastic polyurethane, polyoxymethylene, thermoplastic elastomers, styrene acrylonitrile, and methyl methacrylate-butadiene-styrene.

[0034] In some embodiments, the first thermoplastic polymer comprises a PE, and the second thermoplastic polymer comprises a PP. In some embodiments, the PE is one or more members selected from the group consisting of: an ethylene homopolymer, a copolymer of units derived from ethylene and units derived from one or more of C3-C20 alpha-olefins or mixtures thereof, a copolymer of units derived from ethylene and units derived from one or more of alpha monoolefins comprising polar groups, or combination thereof. In some embodiments, the PP is one or more members selected from the group consisting of: propylene homopolymers, copolymers of units derived from propylene and units derived one or more of ethylene and Ci C20 alpha-olefins or mixtures thereof, or a combination thereof. In some embodiments, the PE is one or more members selected from the group consisting of: EDPE, ELDPE, MDPE, and HDPE. In some embodiments, the PP is one or more members selected from the group consisting of: iPP, RCP, and hPP.

[0035] In some embodiments, the first thermoplastic polymer is present in an amount in the range of from 5 wt% to 95 wt%, from 15 wt% to 85 wt%, or from 25 wt% to 75 wt%, wherein weight percentages are based on the combined weight of the first thermoplastic polymer and the second thermoplastic polymer, and the second thermoplastic polymer is present in an amount in the range of from 5 vrt% to 95 wt%, from 15 wt% to 85 wt%, or from 25 wt% to 75 wt%, wherein weight percentages are based on the combined weight of the first thermoplastic polymer and the second thermoplastic polymer.

[0036] In addition to incompatibility between the first and second thermoplastic polymers, at least one of the first and second thermoplastic polymers comprises a PCR resin, which inherentlycontains some level of a contaminant, which introduces another incompatible material into the blend.Contaminants

[0037] In some embodiments, the first thermoplastic polymer comprises a first contaminant in an amount in the range of from 0 to 10 wt%, wherein wt% is based on the weight of the first thermoplastic polymer. When contaminant is present in the first polymer recyclate, the first polymer recyclate can comprise the first contaminant in an amount in the range of from 0.1 wt% to 8 wt%, from 0.2 wt% to 6 wt%, from 0.3 wt% to 4 wt%, or from 0.5 wt% to 2 wt%. In some embodiments, the second thermoplastic polymer comprises a second contaminant in an amount in the range of from 0 to 10 wt%, wherein wt% is based on the weight of the second thermoplastic polymer. When contaminant is present in the first polymer recyclate, the first polymer recyclate can comprise the first contaminant in an amount in the range of from 0.1 wt% to 8 wt%, from 0.2 wt% to 6 wt%, from 0.3 wt% to 4 wt%, or from 0.5 wt% to 2 wt%.

[0038] In some embodiments, the first and / or second contaminant comprise non-intentionally added substances (NIAS). NIAS materials are impurities from the recycling of plastic waste that are present in PCR resins present as impurities from the recycling plastic waste to produce the first thermoplastic polymer and / or the second thermoplastic polymer. Polarity of a material also plays a crucial role in its compatibility in a polymer blend. Such NIAS materials have some level of polarity and are therefore immiscible with both components of a blend of first and second thermoplastic polymers, such as, but not limited to a blend of a polyethylene and a polypropylene. Due to immiscibility with either component of the blend, these NIAS materials tend to migrate to the interface between the two incompatible thermoplastic polymers.

[0039] NIAS materials can include one or more barner resms, packaging residue, waste residue, or a combination thereof.

[0040] The presence of barrier resins in a PCR resin is a result of the inability to remove at least some portion of packaging and / or containers from waste plastic, wherein such packaging and / or containers comprise one or more barrier layers. Barrier layers are included in packaging and / or containers for improving resistance to gas vapor transmission, and in some cases resistance to oxygen transmission. Barrier resins used are typically polar polymers such as ethylene-vinyl alcohol (EV OH) or polyamide (nylon) resins, and in some instances, polyphenylene oxide (PPO), polyphenylene sulfide (PPS), polyimide, liquid crystal polymer, polyetheretherketone, and / or polyethenmide resms. Other layers may be made from or contain a polyester, such as, but not limited to polyethylene terephthalate (PET), polybutylene terephthalate (PBT), polytrimethylene terephthalate (PTT), and Polyethylene naphthalate (PEN). A barrier layer may comprise one or more polyamides (nylons), ethylene vinyl alcohol copolymers (EVOH), poly vinylidene chloride(PVDF), polycarbonate (PC), MXD6 nylon or combination of two or more thereof. EVOH includes a vinyl alcohol copolymer having 27 to 44 mol % ethylene, and is prepared by, for example, hydrolysis of vinyl acetate copolymers. EVOH is available as Soamol™ from Soarus and EVAL™ from Kuraray. The polyamide can include polyamide 6, polyamide 9, polyamide 10, polyamide 11, polyamide 12, polyamide 6,6, polyamide 6 / 66 and aromatic polyamide such as polyamide 61, polyamide 6T, MXD6, or combinations for two or more thereof.

[0041] Polarity of a polymer also plays a crucial role in the compatibility of polymer blends. Polymers with similar polarities can dissolve in each other and form a homogeneous blend, whereas polymers with different polarities repel each other and form a phase-separated blend. This is because the attractive forces between polar groups are stronger than the repulsive forces between nonpolar groups. Barrier resins comprise polar polymers having a polarity such that they are incompatible with both the first and second thermoplastic resins. All or a portion of such barrier resins have a polarity suitable for reaction with the functional groups of the compatibilizers disclosed herein.

[0042] Packaging residue results from an inability to completely separate a portion of secondary packaging material from plastic waste used to produce a PCR resin. Secondary packaging can include, but is not limited to, cardboard boxes, shrink wrap, bubble wrap, plastic bags, foam inserts, cormgated pads, and labels and stickers. Cardboard boxes are commonly used as secondary packaging for a wide range of products, from food and beverages to electronics and cosmetics. The purpose of cardboard boxes is to protect the primary packaging from damage during transport and storage. Shrink wrap is a type of plastic film that is applied around a product or a group of products and then shrunk using heat. The purpose of shrink wrap is to keep the products clean and protected from dust, moisture, and other contaminants. Bubble wrap is aplastic packaging material that has air-filled bubbles. The purpose of bubble wrap is to cushion the product and protect it from damage during transport. Plastic bags are commonly used as secondary packaging for small products such as snacks, candies, and small toys. The purpose of plastic bags is to keep the products clean and protected from moisture and dust. Foam inserts are often used as secondary packaging for fragile products such as electronics, glassware, and ceramics. The purpose of foam inserts is to cushion the product and protect it from damage during transport. Corrugated pads are flat sheets of corrugated cardboard that are used to separate and cushion products during transport. The purpose of cormgated pads is to protect the products from damage caused by vibration and impact. Labels and stickers are often used as secondary packaging to provide information about the product, such as ingredients, nutritional information, and usage instructions. PCR resin can contain residual amounts of polymers, fibers, fabrics, paper, cellulosic and non-cellulosic waste, and / or other materials resulting from the breakdown of secondarypackaging. All or a portion of such packaging residue has a polarity suitable for reaction with the functional groups of the compatibilizers disclosed herein.

[0043] PCR resins can further comprise waste residue comprising materials unassociated with the primary or secondary packaging materials. Such materials can include, but are not limited to, food waste, dirt, glass, metal, gravel, cloth, oil, bio-waste, soap, detergents, and newspaper. These residual materials result from the inability of the waste plastic sorting and separating process to completely remove generic trash and garbage from recycled waste plastic. All or a portion of such waste has a polarity suitable for reaction with the functional groups of the compatibilizers disclosed herein.Compatibilizer

[0044] The mixture further comprises a compatibilizer. The compatibilizer comprises a third thermoplastic polymer grafted with one or more functional groups, wherein the third thermoplastic polymer is compatible with the first thermoplastic polymer, and a fourth thermoplastic polymer grafted with one or more functional groups wherein the fourth thermoplastic polymer is compatible with the second thermoplastic polymer.

[0045] In some embodiments, the third thermoplastic polymer and / or the fourth thermoplastic polymer are each independently selected from the group consisting of: polyethylene, polypropylene, polyvinyl chloride, polystyrene, acrylonitrile butadiene styrene, fluoropolymers, ethylene vinyl acetate, thermoplastic polyurethane, polyoxymethylene, thermoplastic elastomers, styrene acrylonitrile, and methyl methacrylate-butadiene-styrene.

[0046] In some embodiments, the third thermoplastic polymer comprises a PE, and the fourth thermoplastic polymer comprises a PP. In some embodiments, the PE is one or more members selected from the group consisting of: an ethylene homopolymer, a copolymer of units denved from ethylene and units derived from one or more of C3-C20 alpha-olefins or mixtures thereof, a copolymer of units derived from ethylene and units derived from one or more of alpha monoolefins comprising polar groups, of a combination thereof. In some embodiments, the PP is one or more members selected from the group consisting of: propylene homopolymers, copolymers of units derived from propylene and units derived one or more of ethylene and Ci C20 alpha-olefins or mixtures thereof, or a combination thereof. In some embodiments, the PE is one or more members selected from the group consisting of: LDPE, LLDPE, MDPE, and HDPE. In some embodiments, the PP is one or more members selected from the group consisting of: iPP, RCP, and hPP.

[0047] In some embodiments, the first thermoplastic polymer and the third thermoplastic polymer each comprise a polyethylene and can be the same or different. In some embodimentsthe second thermoplastic polymer and the third thermoplastic polymer each comprise a polypropylene and can be the same or different.

[0048] In some embodiments, a compatibilizer as disclosed herein comprises a modified polymer produced by reacting a polymer with functional groups or monomers, such as acid and / or acid derivative moieties, wherein the polymer has the one or more functional groups or monomers grafted along the polymer chain. In some embodiments the modified polymer is a functionalized polyethylene, a functionalized polypropylene, or a combination thereof.

[0049] In some embodiments, the incompatible blend comprises two incompatible thermoplastic polymers other than polyethylene and polypropylene. In such embodiments, the compatibilizer would comprise a functionalized polymer compatible with one component of the incompatible blend and a second functionalized polymer compatible with the other component of the incompatible blend.

[0050] Functionalized polymers are generally formed by grafting a functional monomer onto the backbone (i. e., main chain) of a polymer, wherein a component of the compatibilizer comprises a functionalized polymer. The composition of the polymer can be any polymer compatible with one component of the incompatible blend. The compatibilizer composition comprises a first compatibilizer component compatible with one component of the incompatible blend and a second compatibilizer component compatible with the other component of the incompatible blend.

[0051] The functional group can be grafted onto the polymer of a compatibilizer component via processes known to one skilled in the art. For example, the graft may be formed via reactive extrusion processes. Reactive extrusion processes generally include contacting the polymer with the functional group within an extruder or in a solution process to form the functionalized polymer.

[0052] The reactive extrusion processes may include any extrusion process known in the art. For example, raw materials (e g., polymer and functional group) may be fed into a twin screw extruder in a concentration sufficient to form the functionalized low polarity polymer having a target graft content. The reaction to form the functionalized low polarity polymer may occur in the twin screw extruder under constant mixing and kneading, for example. Thus, the functionalized polymer generally includes a linear backbone of the polymer with randomly distributed branches of the functional group, resulting in side chains that are structurally distinct from the main chain / backbone.

[0053] In one or more embodiments, the polymer contacts the functional monomer in the presence of an initiator. Initiators can be selected from those known to one skilled in the art, such as, but not limited to, organic peroxides. However, as discussed previously herein, grafting can take place under high temperature and high shear in absence of an initiator.

[0054] In some embodiments, compatibilizers of the invention are conveniently prepared by grafting the polymer in the substantial absence of solvent. This can be accomplished in a shearimparting reactor, such as an extruder / reactor. Twin screw extruder / reactors such as those manufactured by Coperion (formerly Werner-Pfleiderer) under the designations ZSK-53, ZSK-83 and ZSK-92 are commonly used. A free radical generating catalyst, such as an organic peroxide catalyst, can be employed but is not necessary. The grafting reaction is carried out at atemperature selected to minimize or avoid rapid vaporization and consequent losses of the graft monomer and any catalyst that may be employed. The graft monomer concentration in the reactor is typically about 1 to about 5 wt. % based on the total reaction mixture weight. A temperature profile where the temperature of the polymer melt increases gradually through the length of the extruder / reactor up to a maximum in the grafting reaction zone and then decreases toward the reactor exit is preferred. The maximum temperature within the reactor should be such that significant vaporization losses and / or premature decomposition of any peroxide catalyst are avoided. For example, if di-t-butyl peroxide and 2,5-dimethyl-2,5-di-(t-butylperoxy) hexane are used, temperatures within the reactor are maintained at or below about 220°C. Examples of useful peroxide catalysts include: l,l-bis(t-butylperoxy)cyclohexane; n-butyl-4,4-bis(t-butylperoxy- valerate); l,l-bis(t-butylperoxy)-3,3,5-trimethylcyclohexane; 2,2-bis(t-butyl-peroxy)butane; dicumylperoxide; t-butylcumylperoxide; alpha, alpha' -bis(t-butylperoxy-preoxy- isopropyl)benzene; di-t-butylperoxide; 2,5-dimethyl-2,5-di(t-butylperoxy) hexane; and the like. The grafting monomer and any catalyst used are preferably added in neat form to the extruder / reactor.

[0055] In some embodiments, the functionalized polymer is obtained by grafting an ethylemcally unsaturated carboxylic acid or derivative, particularly MAH, onto the polymer backbone. The grafting may be accomplished using known procedures in solution, in a fluidized bed reactor, by melt grafting or by irradiation grafting. As used herein, the term grafting denotes covalent bonding of the grafting monomer to the polymer chain.

[0056] The functionalized polymer may include the functional group in a range of from 0.10 wt% to 2.9 wt%, from 0.45 wt% to 2.8 wt%, from 0.70 wt% to 2.7 wt%, from 1.05 wt% to 2.6 wt%, from 1.50 wt% to 2.5 wt%, wherein weight percentages are based on the total weight of the compatibilizer.

[0057] A functional group for grafting to the third and / or fourth thermoplastic polymer comprises at least one polymenzable, ethylemcally unsaturated carboxylic acid or acid derivative, such as an acid anhydride, ester, salt or the like. Such functional groups include but are not necessarily limited to the following: acrylic acid, methacrylic acid, maleic acid, fumaric acid, itaconic acid, citraconic acid, mesaconic acid, maleic anhydride, 4-methyl cyclohex-4-ene-l,2-dicarboxylic acid anhydride, bicyclo(2.2.2)oct-5-ene-2,3-dicarboxyhc acid anhydride, l,2,3,4,5,8,9,10-octahydronaphthalene-2,3-dicarboxylic acid anhydride, 2-oxa-l,3- diketospiro(4.4)non-7-ene, bicyclo(2.2. l)hept-5-ene-2,3-dicarboxylic acid anhydride, maleopimaric acid, tetrahydrophthalic anhydride, norborn-5-ene-2,3-dicarboxylic acid anhydride, nadic anhydride, methyl nadic anhydride, himic anhydride, methyl himic anhydride, and x-methylbicyclo(2.2.1)hept-5-ene-2,3-dicarboxylic acid anhydride (XMNA). In some embodiments, the functional group selected for grafting is maleic anhydride. Other unsaturated functional groups are described in U.S. Pat. No. 6,385,777 and U.S. Pat. App. Pub. No. 2007 / 0054142, for which the substance of both is fully incorporated herein by reference.

[0058] In some embodiments, the compatibilizer is present in an amount in the range of from 0.1 wt% to 10 wt%, from 0.2 wt% to 8 wt%, from 0.3 wt% to 6 wt%, or from 0.5 wt% to 4 wt%, wherein weight percentages are based on the combined weight of the first thermoplastic polymer and the second thermoplastic polymer.

[0059] In some embodiments, the level of compatibilization provided by the compatibilizer can be influenced by the weight average molecular weight of the third and / or fourth thermoplastic polymers, the amount of long-chain branching of the third and / or fourth thermoplastic polymers, and / or the total and relative amounts of the third and fourth thermoplastic polymers added to the incompatible polymer blend. Additionally, the total amount of contaminants in the incompatible polymer blend can influence the effectiveness of the compatibilizer. For example, a low level of contaminants may hinder the effectiveness of the compatibilizer by not drawing enough compatibilizer to the interface between the first and second thermoplastic polymers. In such cases, an amount of a material having polarity could be added to the blend as a proxy for an additional amount of contaminant.Compounding Conditions

[0060] In some embodiments, mixture is subjected to compounding conditions sufficient to promote a reaction between the one or more functional groups and the first contaminant and / or the second contaminant to form a polymer product comprising a compatibilized blend of the first thermoplastic polymer and the second thermoplastic polymer. Without wishing to be bound by any particular theory, it is believed that all or a portion of the first contaminant and / or the second contaminant are sufficiently polar in character such that the one or more functional groups of the compatibilizer will react during compounding to form a covalent or ionic bond with the first contaminant and / or the second contaminant. This results in the third thermoplastic polymer and the fourth thermoplastic being bonded to the first and / or second contaminants. It is further believed that the polar character of the first and / or second contaminants, being incompatible with the first and second thermoplastic polymers, will migrate to the interface of the first and the secondthermoplastic polymers. Since the third and fourth thermoplastic polymers are bonded to the first and / or second contaminants, the third and fourth thermoplastic polymers will also be migrated to the interface between the first and second thermoplastic polymers where miscibility of the first thermoplastic polymer with the third thermoplastic polymer and miscibility of the second thermoplastic polymer with the fourth thermoplastic polymer functions to compatibilize the blend of the first thermoplastic polymer and the second thermoplastic polymer.

[0061] The compounding conditions will be such that the specific energy from the compounder from shear and / or added heat are sufficient to melt the polymer components and homogenize them. In some embodiments, compounding conditions comprise a temperature in the compounding zone of less than or equal to 300°C, less than or equal to 250°C or less than or equal to 200°C. In some embodiments, where the polymer recyclate comprises a polyethylene, temperatures in the compounding zone can be in the range of from 125°C to 195°C, from 130°C to 180°C, or from 135°C to 165°C. In some embodiments, where the polymer recyclate comprises a polypropylene, temperatures in the compounding zone can be in the range of from 175°C to 245°C, from 180°C to 230°C, or from 185°C to 215°C. In some embodiments, where the polymer recyclate comprises a thermoplastic polymer other than polyethylene or polypropylene, temperatures in the compounding zone can be in the range of from the melting temperature (Tm) of the thermoplastic polymer to the temperature at which the thermoplastic polymer will begin to degrade (Td), from Tm plus 10°C to Ta minus 10°C, from Tmplus 20°C to Ta minus 20°C, or from Tmplus 30°C to Ta minus 30°C. The polymer recyclate can be pelletized for later mixing a compatibilizer as described below or can be blended in the melted state with such compatibilizer.

[0062] In some embodiments, a method for compatibilizing a polymer blend comprises combining a first thermoplastic polymer, a second thermoplastic polymer, and a compatibilizer to form a mixture. The first thermoplastic polymer and / or the second thermoplastic polymer each comprise a contaminant in an amount in the range of from 0 to 5 wt%, wherein weight percentages are based on the weight of the first thermoplastic polymer and the second thermoplastic polymer, respectively. When contaminant is present in the first polymer recyclate, the first polymer recyclate can comprise the first contaminant in an amount in the range of from 0. 1 wt% to 8 wt%, from 0.2 wt% to 6 wt%, from 0.3 wt% to 4 wt%, or from 0.5 wt% to 2 wt%. The second thermoplastic polymer comprises a second contaminant in an amount in the range of from 0 to 10 wt%, wherein wt% is based on the weight of the second thermoplastic polymer. When contaminant is present in the first polymer recyclate, the first polymer recyclate can comprise the first contaminant in an amount in the range of from 0.1 wt% to 8 wt%, from 0.2 wt% to 6 wt%, from 0.3 wt% to 4 wt%, or from 0.5 wt% to 2 wt%. The second thermoplastic polymer is incompatible with the first thermoplastic polymer. The compatibilizer comprises a thirdthermoplastic polymer, grafted with one or more functional groups, and a fourth thermoplastic polymer, grafted with one or more functional groups. The third thermoplastic polymer is compatible with the first thermoplastic polymer, and the fourth thermoplastic polymer is compatible with the second thermoplastic polymer.Certain Embodiments

[0063] In some embodiments, a compatibilized blend of incompatible polymers comprises a mixture of a first thermoplastic polymer and a second thermoplastic polymer. The first and second thermoplastic polymers are incompatible. The first thermoplastic polymer comprises a first contaminant in an amount in the range of from 0 to 10 wt%, wherein wt% is based on the weight of the first thermoplastic polymer. The second thermoplastic polymer comprises a second contaminant in an amount in the range of from 0 to 10 wt%, wherein wt% is based on the weight of the second thermoplastic polymer.

[0064] The mixture further comprises a compatibilizer. The compatibilizer comprises a third thermoplastic polymer grafted with one or more functional groups, wherein the third thermoplastic polymer is compatible with the first thermoplastic polymer, and a fourth thermoplastic polymer grafted with one or more functional groups wherein the fourth thermoplastic polymer is compatible with the second thermoplastic polymer. The first thermoplastic polymer comprises greater than 0 wt% of the first contaminant and / or the second thermoplastic polymer comprises greater than 0 wt% of the second contaminant. The mixture is subjected to compounding conditions sufficient to promote a reaction between the one or more functional groups and the first contaminant and / or the second contaminant to form a polymer product comprising a compatibilized blend of the first thermoplastic polymer and the second thermoplastic polymer.

[0065] In some embodiments of the composition, in addition to the above limitations, the composition is further characterized by one or more of the following: a) the first thermoplastic polymer is a first polymer recy elate, and the first contaminant is present in the first polymer recyclate in an amount in the range of from 0.1 wt% to 8 wt%, from 0.2 wt% to 6 wt%, from 0.3 wt% to 4 wt%, or from 0.5 wt% to 2 wt%; b) the second thermoplastic polymer is a second polymer recyclate, and the second contaminant is present in the second polymer recyclate in an amount in the range of from 0. 1 wt% to 8 wt%, from 0.2 wt% to 6 wt%, from 0.3 wt% to 4 wt%, or from 0.5 wt% to 2 wt%; c) the first thermoplastic polymer, the second thermoplastic polymer, the third thermoplastic polymer, and the fourth thermoplastic polymer are each independently selected from the group consisting of: polyethylene, polypropylene, polyvinyl chloride, polystyrene, acrylonitrile butadiene styrene, fluoropolymers, ethylene vinylacetate, thermoplastic polyurethane, polyoxymethylene, thermoplastic elastomers, styrene acrylonitrile, and methyl methacrylate-butadiene-styrene, wherein the first and second thermoplastic polymers are incompatible, the first and third thermoplastic polymers are compatible, and the second and fourth thermoplastic polymers are compatible; d) the first thermoplastic polymer comprises a PE, and the second thermoplastic polymer comprises a PP, wherein: i) in some embodiments, the PE is one or more members selected from the group consisting of: an ethylene homopolymer, a copolymer of units derived from ethylene and units derived from one or more of C3-C20 alpha-olefins or mixtures thereof, a copolymer of units derived from ethylene and units derived from one or more of alpha mono-olefins comprising polar groups, ii) PE is one or more members selected from the group consisting of: LDPE, LLDPE, MDPE, and HDPE; iii) PP is a propylene homopolymers, a copolymers of units derived from propylene and units derived one or more of ethylene and C4 C20 alpha-olefins or mixtures thereof, or a combination thereof; and / or iv) PP is one or more members selected from the group consisting of: iPP, RCP, and hPP; e) the first contaminant and the second contaminant comprise non-intentionally added substances (NIAS) present as impurities from the recycling of the first thermoplastic polymer and / or the second thermoplastic polymer, respectively, wherein in some embodiments the NIAS comprises one or more barrier resins, packaging residue, waste residue, or a combination thereof; f) the first thermoplastic polymer is present in an amount in the range of from 5 wt% to 95 wt%, from 15 wt% to 85 wt%, or from 25 wt% to 75 wt%, wherein weight percentages are based on the combined weight of the first thermoplastic polymer and the second thermoplastic polymer; g) the second thermoplastic polymer is present in an amount in the range of from 5 wt% to 95 wt%, from 15 wt% to 85 wt%, or from 25 wt% to 75 wt%, wherein weight percentages are based on the combined weight of the first thermoplastic polymer and the second thermoplastic polymer; h) the compatibilizer is present in an amount in the range of from 0.1 wt% to 10 wt%, from 0.2 wt% to 8 wt%, from 0.3 wt% to 6 wt%, or from 0.5 wt% to 4 wt%, whereinweight percentages are based on the combined weight of the first thermoplastic polymer and the second thermoplastic polymer; i) compounding conditions comprise temperature, pressure, and shear force conditions implemented in an extruder to provide melting and intimate mixing of two or more polymers,. j) compounding conditions comprise a temperature of less than or equal to 300°C, less than or equal to 250°C; k) the first thermoplastic polymer and the second thermoplastic polymers are polyethylenes, and compounding conditions comprise a temperature less than or equal to 200°C, or in the range of from 125°C to 195°C, from 130°C to 180°C, or from 135°C to 165°C; l) the first thermoplastic polymer and / or the second thermoplastic polymers are polypropylenes, and compounding conditions comprise a temperature less than or equal to 250°C, or in the range of from 175°C to 245°C, from 180°C to 230°C, or from 185°C to 215°C; m) the first thermoplastic polymer and the third thermoplastic polymer each comprise a polyethylene and can be the same or different; and n) the second thermoplastic polymer and the third thermoplastic polymer each comprise a polypropylene and can be the same or different.

[0066] In some embodiments, a method for compatibilizing a polymer blend comprises combining a first thermoplastic polymer, a second thermoplastic polymer, and a compatibilizer to form a mixture. The first thermoplastic polymer and / or the second thermoplastic polymer each comprise a contaminant in an amount in the range of from 0 to 5 wt%, wherein weight percentages are based on the weight of the first thermoplastic polymer and the second thermoplastic polymer, respectively. The second thermoplastic polymer is incompatible with the first thermoplastic polymer. The compatibilizer comprises a third thermoplastic polymer, grafted with one or more functional groups, and a fourth thermoplastic polymer, grafted with one or more functional groups. The third thermoplastic polymer is compatible with the first thermoplastic polymer, and the fourth thermoplastic polymer is compatible with the second thermoplastic polymer.

[0067] The mixture is subjected to compounding conditions sufficient to promote a reaction between the one or more functional groups and the contaminant to form a polymer product comprising a compatibihzed blend of the first thermoplastic polymer and the second thermoplastic polymer.

[0068] In some embodiments of the method, in addition to the above limitations, the method is further characterized by one or more of the following:a) the first thermoplastic polymer is a first polymer recyclate, and the first contaminant is present in the first polymer recyclate in an amount in the range of from 0.1 wt% to 8 wt%, from 0.2 wt% to 6 wt%, from 0.3 wt% to 4 wt%, or from 0.5 wt% to 2 wt%; b) the second thermoplastic polymer is a second polymer recyclate, and the second contaminant is present in the second polymer recyclate in an amount in the range of from 0. 1 wt% to 8 wt%, from 0.2 wt% to 6 wt%, from 0.3 wt% to 4 wt%, or from 0.5 wt% to 2 wt%; c) the first thermoplastic polymer, the second thermoplastic polymer, the third thermoplastic polymer, and the fourth thermoplastic polymer are each independently selected from the group consisting of: polyethylene, polypropylene, polyvinyl chloride, polystyrene, acrylonitrile butadiene styrene, fluoropolymers, ethylene vinyl acetate, thermoplastic polyurethane, polyoxymethylene, thermoplastic elastomers, styrene acrylonitrile, and methyl methacrylate-butadiene-styrene; d) the first thermoplastic polymer comprises a PE, and the second thermoplastic polymer comprises a PP, wherein: i) in some embodiments, the PE is one or more members selected from the group consisting of: an ethylene homopolymer, a copolymer of units derived from ethylene and units derived from one or more of C3-C20 alpha-olefins or mixtures thereof, a copolymer of units derived from ethylene and units derived from one or more of alpha mono-olefins comprising polar groups, ii) PE is one or more members selected from the group consisting of: LDPE, LLDPE, MDPE, and HDPE;111) PP is a propylene homopolymers, a copolymers of units derived from propylene and units derived one or more of ethylene and C4 C20 alpha-olefins or mixtures thereof, or a combination thereof; and / or iv) PP is one or more members selected from the group consisting of: iPP, RCP, and hPP; e) the first contaminant and the second contaminant comprise non-intentionally added substances (NIAS) present as impurities from the recycling of the first thermoplastic polymer and / or the second thermoplastic polymer, respectively, wherein in some embodiments the NIAS comprises one or more barrier resins, packaging residue, waste residue, or a combination thereof; f) the first thermoplastic polymer is present in an amount in the range of from 5 wt% to 95 wt%, from 15 wt% to 85 v %, or from 25 wt% to 75 wt%, wherein weightpercentages are based on the combined weight of the first thermoplastic polymer and the second thermoplastic polymer; g) the second thermoplastic polymer is present in an amount in the range of from 5 wt% to 95 wt%, from 15 wt% to 85 v %, or from 25 wt% to 75 wt%, wherein weight percentages are based on the combined weight of the first thermoplastic polymer and the second thermoplastic polymer; h) the compatibilizer is present in an amount in the range of from 0.1 wt% to 10 wt%, from 0.2 wt% to 8 wt%, from 0.3 wt% to 6 wt%, or from 0.5 wt% to 4 wt%, wherein weight percentages are based on the combined weight of the first thermoplastic polymer and the second thermoplastic polymer; i) compounding conditions comprise temperature, pressure, and shear force conditions implemented in an extruder to provide melting and intimate mixing of two or more polymers,. j) compounding conditions comprise a temperature of less than or equal to 300°C, less than or equal to 250°C; k) the first thermoplastic polymer and the second thermoplastic polymers are polyethylenes, and compounding conditions comprise a temperature less than or equal to 200°C, or in the range of from 125°C to 195°C, from 130°C to 180°C, or from 135°C to 165°C; l) the first thermoplastic polymer and / or the second thermoplastic polymers are polypropylenes, and compounding conditions comprise a temperature less than or equal to 250°C, or in the range of from 175°C to 245°C, from 180°C to 230°C, or from 185°C to 215°C; m) the first thermoplastic polymer and the third thermoplastic polymer each comprise a polyethylene and can be the same or different; and n) the second thermoplastic polymer and the third thermoplastic polymer each comprise a polypropylene and can be the same or different.EXAMPLES

[0069] The following examples are included to demonstrate preferred embodiments of the invention. It should be appreciated by those of skill in the art that the techniques disclosed in the examples which follow represent techniques discovered by the inventor to function well in the practice of the invention, and thus can be considered to constitute preferred modes for its practice. However, those of skill in the art should, in light of the present disclosure, appreciate that many changes can be made in the specific embodiments which are disclosed and still obtain a like or similar result without departing from the spirit and scope of the invention.Test Methods

[0070] Densities are determined in accordance with ASTM D-792 andASTM D-1505 / ISO-1183.

[0071] Dart drop (g): Measurements were made following ASTM DI 709-04 (2016), using a dart drop height of 26 in (F50).

[0072] Elongation at break (%): Elongation at break was measured according to ASTM D-638.

[0073] Elmendorf Tear (g / mil) was made according to ASTMD 1922.

[0074] Gardner Impact is measured as specified by ASTM D4226, D5420.

[0075] Gloss (45°) is measured as specified by ASTM D2457.

[0076] Haze (%): Film haze measurements were made following ASTM DI 003.

[0077] Melt index (“I2”) was determined by ASTM D-1238-E (190°C / 2.16 kg).

[0078] Narrow Angle Scatter: Film NAS measurements were made following ASTM D1746 (2015) Standard Test Method for Transparency of Plastic Sheeting. 0079] Uniloy™ 5630 processability: Bottle swell properties were determined using one gallon bleach-type bottles produced using a reciprocating Uniloy™ 5630 (single head) blow molder with the following heat settings:

[0080] The melt temperature under these conditions was 193°C. Screw speed was maintained at 26 rpm and the total cycle time was 15.4 seconds (10 seconds blow and 1.5 seconds parison drop). High-shear processability and swell changes were determined from bottles produced on a Uniloy™ 5630 intermittent extrusion blow molder - 1-gal milk / water bottles from homopolymers. Swell was measured by two methods. Weight swell was determined by the initial weight change observed for a test resin after transitioning from the control. Diameter swell was determined by measuring on an inlaid centimeter scale the distance of the flash down the handle of the bottle after the bottle weight had been reset at the target weight.

[0081] Tensile stress at break (MPa): Tensile stress at break was measured according to ASTM D-638. This test is dependent on film sample thickness. For the measurements provided here, a thickness of about 46 pm to 55 pm was used.Materials used in experimentsStarting materials

[0082] Starting materials for Examples 1-14 are shown in TABLE 1 below.TABLE 11 Melt index, 2.16 g @ 190°C2 Melt flow rate, 5 g @ 230°C3 Melt flow rate, 2.16 g @ 230°C- Incompatible polymer blends

[0083] Proxies for incompatible blends comprising one or more PCR resins could be prepared as shown in Table 2 shows. Each of Examples 1 -10 comprise a polyethylene, a polypropylene, and portion of nylon to simulate a contaminant. The blends could be compounded at 165°C. Mixing in the extruder could be sufficient to form pellets having an average size in the range of from 20 to 60 pellets per gram, wherein the pellets were compositionally equivalent.* All weight percentages based on the combined weight of the polyethylene component and the polyethylene component being 100%.Compatibilizer

[0084] Table 2 shows compatibilizer components that could be produced by the methods disclosed herein. Compatibilizer component Cl would be miscible with polyethylene portion of the incompatible blends IB1-IB12. Compatibilizer component C2 would be miscible with polypropylene portion of the incompatible blends IB1-IB12.TABLE 3Compatibilized polymer blends

[0085] Table 3 shows compatibilized blends comprising the incompatible blends IB1-IB12 and compatibilizer components Cl and C2. The amounts of polyethylene compatibilizer component Cl and polypropylene compatibilizer component C2 in the compatibilizer composition could correspond to the amounts of polyethylene and polypropylene in incompatible blends IB1- IB12, respectively.TABLE 4All weight percentages based on the weight of the incompatible blend being 100%.

[0086] Comparison of inventive Examples 13-24 to comparative Examples 1-12 would show that would show compatibilized blends CB1-CB12 exhibit a measurable improvement in one ormore of dart drop (ASTM D1709-04), elongation at break (ASTM D-638), Elmendorf tear (ASTM D 1922), gloss (ASTM D2457), Gardner impact (ASTM D4226, D5420), haze (ASTM D1003), clarity (ASTM DI 746), processability (Uniloy™ 5630 processability test), and tensile stress at break (ASTM D-638), when compared to their counterpart incompatible blends IB 1 -IB 12, respectively.

[0087] For the sake of brevity, only certain ranges are explicitly disclosed herein. However, in addition to recited ranges, any lower limit may be combined with any upper limit to recite a range not explicitly recited, as well as, ranges from any lower limit may be combined with any other lower limit to recite a range not explicitly recited, in the same way, ranges from any upper limit may be combined with any other upper limit to recite a range not explicitly recited. Additionally, within a range includes every point or individual value between its end points even though not explicitly recited. Thus, every point or individual value may serve as its own lower or upper limit combined with any other point or individual value or any other lower or upper limit, to recite a range not explicitly recited.

[0088] All documents and references cited herein, including testing procedures, publications, patents, journal articles, etc., are herein fully incorporated by reference for all jurisdictions in which such incorporation is permitted and to the extent such disclosure is consistent with the description of the present invention.

[0089] Although the present invention and its advantages have been described in detail, it should be understood that various changes, substitutions and alterations can be made herein without departing from the spirit and scope of the invention as defined by the appended claims. Moreover, the scope of the present application is not intended to be limited to the particular embodiments of the processes, machines, film structures, composition of layers, means, methods, and / or steps described in the specification. As one of the ordinary skill in the art will readily appreciate from the disclosure of the present invention, processes, machines, film structures, composition of layers, means, methods, and / or steps, presently existing or later to be developed that perform substantially the same function or achieve substantially the same result as the corresponding embodiments described herein, may be utilized according to the present invention. Accordingly, the appended claims are intended to include within their scope such processes, machines, film structures, composition of layers, means, methods, and / or steps.

Claims

CLAIMSWhat is claimed is:

1. A composition comprising a mixture of: a) a first thermoplastic polymer, comprising a first contaminant in an amount in the range of from 0 to 10 wt%, wherein wt% is based on the weight of the first thermoplastic polymer; b) a second thermoplastic polymer, compnsing a second contaminant in an amount in the range of from 0 to 10 wt%, wherein wt% is based on the weight of the second thermoplastic polymer, wherein the second thermoplastic polymer is incompatible with the first thermoplastic polymer; c) a compatibilizer, comprising: i) a third thermoplastic polymer grafted with one or more functional groups, wherein the third thermoplastic polymer is compatible with the first thermoplastic polymer; and ii) a fourth thermoplastic polymer grafted with one or more functional groups wherein the fourth thermoplastic polymer is compatible with the second thermoplastic polymer; wherein: the first thermoplastic polymer comprises greater than 0 wt% of the first contaminant and / or the second thermoplastic polymer comprises greater than 0 wt% of the second contaminant; and the mixture is subjected to compounding conditions sufficient to promote a reaction between the one or more functional groups and the first contaminant and / or the second contaminant to form a polymer product comprising a compatibilized blend of the first thermoplastic polymer and the second thermoplastic polymer.

2. The composition of claim 1, wherein the first thermoplastic polymer, the second thermoplastic polymer, the third thermoplastic polymer, and the fourth thermoplastic polymer are each independently selected from the group consisting of: polyethylene, polypropylene, polyvinyl chloride, polystyrene, acrylonitrile butadiene styrene, fluoropolymers, ethylene vinyl acetate, thermoplastic polyurethane, polyoxymethylene, thermoplastic elastomers, styrene acrylonitrile, and methyl methacrylate-butadiene-styrene.

3. The composition of claim 1, wherein: a) the first thermoplastic polymer and the third thermoplastic polymer, are each independently selected from the group consisting of: an ethylene homopolymer, acopolymer of units derived from ethylene and units derived from one or more of Cs- C20 alpha-olefins or mixtures thereof, a copolymer of units derived from ethylene and units derived from one or more of alpha mono-olefins comprising polar groups, or a combination thereof; and b) the second thermoplastic polymer and the fourth thermoplastic polymer are each independently selected from the group consisting of: a propylene homopolymer, a copolymers of units derived from propylene and units derived one or more of ethylene and C4-C20 alpha-olefins or mixtures thereof, or a combination thereof.

4. The composition of claim 1, wherein the first contaminant and the second contaminant comprise non-intentionally added substances (NIAS) present as impurities from the recycling of the first thermoplastic polymer and / or the second thermoplastic polymer.

5. The composition of claim 4, wherein the NIAS comprises one or more barrier resins, packaging residue, waste residue, or a combination thereof.

6. The composition of claim 1, wherein the one or more functional groups comprise a member selected from the group consisting of an anhydride, a carboxylic acid, and combinations thereof.

7. The composition of claim 1, wherein: a) the first thermoplastic polymer is present in an amount in the range of from 5 wt% to 95 wt% b) the second thermoplastic polymer is present in an amount in the range of from 5 wt% to 95 wt%; and c) the compatibilizer is present in an amount in the range of from 0. 1 wt% to 10 wt%; wherein weight percentages are based on the combined weight of the first thermoplastic polymer and the second thermoplastic polymer.

8. The composition of claim 1, wherein compounding conditions comprise temperature, pressure, and shear force conditions implemented in an extruder to provide melting and intimate mixing of two or more polymers.

9. The composition of claim 1, wherein compounding conditions comprise a temperature of less than or equal to 300°C.

10. The composition of claim 1, wherein: a) the first thermoplastic polymer and the third thermoplastic polymer each comprise a polyethylene and can be the same or different; and b) the second thermoplastic polymer and the third thermoplastic polymer each comprise a polypropylene and can be the same or different.

11. A method for compatibilizing a polymer blend, the method comprising: a) combining a first thermoplastic polymer, a second thermoplastic polymer, and a compatibilizer to form a mixture, wherein: i) the first thermoplastic polymer and / or the second thermoplastic polymer each comprise a contaminant in an amount in the range of from 0 to 10 wt%, wherein weight percentages are based on the weight of the first thermoplastic polymer and the second thermoplastic polymer, respectively; ii) the second thermoplastic polymer is incompatible with the first thermoplastic polymer; and in) the compatibilizer comprises:(1) a third thermoplastic polymer grafted with one or more functional groups, wherein the third thermoplastic polymer is compatible with the first thermoplastic polymer; and(2) a fourth thermoplastic polymer grafted with one or more functional groups wherein the fourth thermoplastic polymer is compatible with the second thermoplastic polymer; b) subjecting the mixture to compounding conditions sufficient to promote a reaction between the one or more functional groups and the contaminant to form a polymer product comprising a compatibilized blend of the first thermoplastic polymer and the second thermoplastic polymer.

12. The method of claim 1 1 , wherein the first thermoplastic polymer, the second thermoplastic polymer, the third thermoplastic polymer, and the fourth thermoplastic polymer are each independently selected from the group consisting of: polyethylene, polypropylene, polyvinyl chloride, polystyrene, acrylonitrile butadiene styrene, fluoropolymers, ethylene vinyl acetate, thermoplastic polyurethane, polyoxymethylene, thermoplastic elastomers, styrene acrylonitrile, and methyl methacrylate-butadiene-styrene.

13. The method of claim 11, wherein: a) the first thermoplastic polymer and the third thermoplastic polymer, are each independently selected from the group consisting of: an ethylene homopolymer, a copolymer of units derived from ethylene and units derived from one or more of Cs- C20 alpha-olefins or mixtures thereof, a copolymer of units derived from ethylene and units derived from one or more of alpha mono-olefins comprising polar groups, or a combination thereof; andb) the second thermoplastic polymer and the fourth thermoplastic polymer are each independently selected from the group consisting of: a propylene homopolymer, a copolymers of units derived from propylene and units derived one or more of ethylene and C4-C20 alpha-olefins or mixtures thereof, or a combination thereof.

14. The method of claim 11, wherein the first contaminant and the second contaminant comprise non-intentionally added substances (NIAS) present as impurities from the recycling of the first thermoplastic polymer and / or the second thermoplastic polymer.

15. The method of claim 14, wherein the NIAS comprises one or more barrier resins, packaging residue, waste residue, or a combination thereof.

16. The method of claim 11, wherein the one or more functional groups comprise a member selected from the group consisting of an anhydride, a carboxylic acid, and combinations thereof.

17. The method of claim 11, wherein: a) the first thermoplastic polymer is present in an amount in the range of from 5 wt% to 95 wt%; b) the second thermoplastic polymer is present in an amount in the range of from 5 wt% to 95 wt%; and c) the compatibilizer is present in an amount in the range of from 0. 1 wt% to 10 wt%; wherein weight percentages are based on the combined weight of the first thermoplastic polymer and the second thermoplastic polymer.

18. The method of claim 11, wherein compounding conditions comprise temperature, pressure, and shear force conditions implemented in an extruder to provide melting and intimate mixing of two or more polymers.

19. The method of claim 18, wherein compounding conditions comprise a temperature of less than or equal to 300°C.

20. The method of claim 11, wherein: a) the first thermoplastic polymer and the third thermoplastic polymer each comprise a polyethylene and can be the same or different; and b) the second thermoplastic polymer and the third thermoplastic polymer each comprise a polypropylene and can be the same or different.

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