Recyclable polyolefin films and laminates
By incorporating virgin ethylene-based polymers as compatibilizers into the recycling process, the challenges of recycling polyolefin films and laminates due to incompatible adhesives and coatings are addressed, achieving improved mechanical performance and recyclability of the materials.
Patent Information
- Application Number
- PCT/US2024/057246
- Authority / Receiving Office
- WO · WO
- Patent Type
- Applications
- Current Assignee / Owner
- Priority Date
- 2023-11-30
- Filing Date
- 2024-11-25
- Publication Date
- 2025-06-05
AI Technical Summary
The challenge in recycling plastic products is the presence of adhesives and coatings that are not chemically compatible with polyolefins, leading to the formation of micron- to millimeter-sized gels in recycled plastics, which undermines the mechanical performance and recyclability of the materials.
Incorporating compatibilizers, such as virgin ethylene-based polymers, into the recycling process of polyolefin films and laminates to improve the mechanical properties and recyclability of post-consumer recycled materials by enhancing the integration of adhesives and coatings with polyolefins.
The use of compatibilizers allows for the effective recycling of polyolefin films and laminates, maintaining at least 67% of the mechanical performance of the original materials, and enabling the production of high-quality recycled articles suitable for various applications.
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Abstract
Description
85651-WO-PCT / DOW 85651 WO 1 RECYCLABLE POLYOLEFIN FILMS AND LAMINATES CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application Serial No. 63 / 604,480 filed November 30, 2023, the contents of which are incorporated in their entirety herein. TECHNICAL FIELD
[0002] The present invention is related to an article having a recyclability property; and more specifically, the present invention is related to an article, including a combination of a polyolefin polymer, adhering or coating auxiliaries, and at least one compatibilizer having a recyclability property. BACKGROUND
[0003] The use of plastic products, for example, packaging materials for the packaging industry, has significantly increased globally. Consequently, the increase in demand for plastic products has created a significant increase in plastic waste because after a plastic product has been used by the consumer the plastic product is discarded by the consumer. The plastic waste detrimentally impacts the environment and landscape throughout the world. To alleviate or reduce the plastic waste problem, manufacturers have attempted to produce a plastic product that can be recycled and reprocessed into other subsequent plastic products after the original plastic product has been used for its original purpose. However, many plastics include adhesives and / or coatings which are typically not chemically compatible with polyolefins forming the remainder of the plastic article. This results in challenges during attempted recycling as the incompatible adhesives and / or coatings appear in micron- to millimeter-sized gels in the resins and films generated from the recycled plastics. The gels can severely undermine the appearance and mechanical performance of the newly formed articles and films and in some situations, the presence of gels makes extrusion impossible. SUMMARY85651-WO-PCT / DOW 85651 WO 2
[0004] Accordingly, there is an ongoing need for the development of a plastic product which includes adhesives and / or coatings which is fully recyclable. To meet these needs, compatibilizers may be included during formation of recycled polymer compositions to improve the mechanical properties of post-consumer recycled films containing adhering or coating auxiliaries such as adhesives and / or coatings. The current commercial recycling of waste plastics typically involves mixing the reclaimed plastics with virgin plastics in a variety of reclaimed:virgin ratios, spanning from 1:99 to 99:1 by weight. In accordance with various aspects of the present disclosure, compatibilizers can be used in a masterbatch of virgin polyethylene resins that can be blended with reclaimed flexible packages to produce post-consumer recycled packaging films. Alternatively, the compatibilizers can be incorporated into the flexible packages during original manufacture allowing the flexible packages to be directly recycled without other additives or aids such as the compatibilizer. The compatibilizers can be in a distinct layer by itself, or can be distributed in the polyethylene resins.
[0005] According to at least one embodiment of the present disclosure, a first article having a recyclability property is provided. The first article includes (a) at least one polyolefin polymer; (b) one or more adhering or coating auxiliaries; and (c) at least one compatibilizer. The compatibilizer includes virgin ethylene-based polymer, wherein the virgin ethylene-based polymer is the polymerized reaction product of ethylene optionally copolymerized and / or grafted with one or more polar comonomers. Further, the compatibilizer is provided in the first article at 1 to 15% by weight of the first article.
[0006] According to at least one embodiment of the present disclosure, a laminate having a recyclability property is provided. The laminate includes (a) at least one first polymer film layer, the first polymer film layer comprising a first polyolefin polymer; (b) at least one second polymer film layer, the second polymer film layer comprising a second polyolefin polymer; (c) one or more adhesives; and (d) at least one compatibilizer. The compatibilizer includes virgin ethylene-based polymer, wherein the virgin ethylene-based polymer is the polymerized reaction product of ethylene optionally copolymerized and / or grafted with one or more polar comonomers. Further, the one or more adhesives include one or more inorganic fillers, bio-derived tree resins and waxes, polypropylene, poly(vinyl acetate)-co-polyethylenes, polyesters, acrylics, or polyurethanes. Additionally, the one or more adhesives are compatible with the at least one first polymer film layer and the at least one second polymer film layer. Finally, the layer of the one or more85651-WO-PCT / DOW 85651 WO 3 adhesives is disposed on the surface of at least one of the layers of the first polymer film layer and the second polymer film layer for binding the first polymer film layer and the second polymer film layer together.
[0007] According to at least one embodiment of the present disclosure, a coated film having a recyclability property is provided. The coated film includes (a) at least one first polymer film layer, the first polymer film layer comprising a first polyolefin polymer; (b) one or more adhering or coating auxiliaries comprising one or more components selected from poly(vinyl acetate)-co-polyethylenes, polyesters, acrylics, and polyurethane; and (c) at least one compatibilizer. The compatibilizer includes virgin ethylene-based polymer, wherein the virgin ethylene-based polymer is the polymerized reaction product of ethylene optionally copolymerized and / or grafted with one or more polar comonomers. Further, the one or more adhering or coating auxiliaries are provided as a coating layer on the surface of the first polymer film layer.
[0008] According to at least one embodiment of the present disclosure, a process for recycling a polyolefin film or laminate is provided. The process includes (A) providing a polyolefin film or laminate, wherein the polyolefin film or laminate is PCR or PIR and comprises at least one polyolefin polymer and one or more adhering or coating auxiliaries; (B) fragmenting the polyolefin film or laminate from step (A) to produce a plurality of fragments of a predetermined size; (C) pelletizing the plurality of fragments from step (B) along with at least one compatibilizer to form a plurality of pellets of a predetermined size. The compatibilizer comprises virgin ethylene-based polymer which is the polymerized reaction product of ethylene copolymerized and / or grafted with one or more polar comonomers. The compatibilizer may be provided as part of the polyolefin film or laminate or may be provided as a separate masterbatch during pelletizing.
[0009] These and other embodiments are described in more detail in the following Detailed Description. DETAILED DESCRIPTION
[0010] Specific embodiments of the present application will now be described. These embodiments are provided so that this disclosure will be thorough and complete and will fully convey the scope of the subject matter to those skilled in the art.85651-WO-PCT / DOW 85651 WO 4
[0011] The term “recyclable” or “recyclability” herein, with reference to a first article including one or more adhering or coating auxiliaries and at least one compatibilizer, means mechanically recyclable or mechanical recyclability; and means the first article including the one or more adhering or coating auxiliaries and the compatibilizer is mechanically re-processable to generate a second article having a desirable performance range, wherein the second article has at least a less than 33 % decreased change in mechanical performance relative to the performance of a control article that is without any of the one or more adhering or coating auxiliaries and compatibilizer(s) and that is reprocessed the same way as the second article. An example, and not to be limited thereby, of testing methods and guidelines for determining recyclability of a plastic article can be found in publication “Critical Guidance Protocol for PE Film and Flexible Packaging”, Document Number FPE-CG-01 (Revision date – August 2, 2022) of The Association of Plastic Recyclers (APR).
[0012] The term “composition,” as used herein, refers to a mixture of materials which comprises the composition, as well as reaction products and decomposition products formed from the materials of the composition.
[0013] “Polymer” means a polymeric compound prepared by polymerizing monomers, whether of the same or a different type. The generic term polymer thus embraces the term homopolymer (employed to refer to polymers prepared from only one type of monomer, with the understanding that trace amounts of impurities can be incorporated into the polymer structure), and the term interpolymer as defined hereinafter. Trace amounts of impurities (for example, catalyst residues) may be incorporated into and / or within the polymer. A polymer may be a single polymer, a polymer blend or a polymer mixture, including mixtures of polymers that are formed in situ during polymerization.
[0014] The term “interpolymer,” as used herein, refers to polymers prepared by the polymerization of at least two different types of monomers. The generic term interpolymer thus includes copolymers (employed to refer to polymers prepared from two different types of monomers), and polymers prepared from more than two different types of monomers.
[0015] The terms “olefin-based polymer” or “polyolefin”, as used herein, refer to a polymer that comprises, in polymerized form, a majority amount of olefin monomer, for example85651-WO-PCT / DOW 85651 WO 5 ethylene or propylene (based on the weight of the polymer), and optionally may comprise one or more comonomers.
[0016] The term, “ethylene / a-olefin interpolymer,” as used herein, refers to an interpolymer that comprises, in polymerized form, a majority amount (e.g., greater than [>] 50 mole percent [mol %]) of units derived from ethylene monomer, and the remaining units derived from one or more a-olefins. Typical a-olefins used in forming ethylene / a-olefin interpolymers are C3-C10 alkenes.
[0017] The term, “ethylene / a-olefin copolymer,” as used herein, refers to a copolymer that comprises, in polymerized form, a majority amount (> 50 mol %) of ethylene monomer, and an a-olefin, as the only two monomer types.
[0018] The term “a-olefin”, as used herein, refers to an alkene having a double bond at the primary or alpha (a) position.
[0019] “Polyethylene (PE)” or “ethylene-based polymer” shall mean polymers comprising a majority amount (> 50 mol %) of units which have been derived from ethylene monomer. This includes polyethylene homopolymers, ethylene / a-olefin interpolymers, and ethylene / a-olefin copolymers. Common forms of polyethylene known in the art include low density polyethylene (LDPE); linear low density polyethylene (LLDPE); ultra low density polyethylene (ULDPE); very low density polyethylene (VLDPE); medium density polyethylene (MDPE); high density polyethylene (HDPE); enhanced polyethylene; polyethylene elastomers; and polyethylene plastomers. These PE materials are generally known in the art; however, the following descriptions may be helpful in understanding the differences between some of these different PE resins. The term “LDPE” may also be referred to as “high pressure ethylene polymer” or “highly branched polyethylene” and is defined to mean that the polymer is partly or entirely homopolymerized or copolymerized in autoclave or tubular reactors at pressures above 14,500 pounds per square inch (psi) (100 megapascal [MPa]) with the use of free-radical initiators, such as peroxides (see for example U.S. Patent Nos. 8,916,667; 8,871,887; 8,822,601; 9,228,036; and 9,765,160). LDPE resins typically have a density in the range of 0.916 grams per cubic centimeter (g / cm3) to 0.935 g / cm3.85651-WO-PCT / DOW 85651 WO 6
[0020] The term “LLDPE”, includes both resins made using the traditional Ziegler-Natta catalyst systems and chromium-based catalyst systems as well as single-site catalysts, including, but not limited to, bis-metallocene catalysts (sometimes referred to as “m-LLDPE”), constrained geometry catalysts (CGC), and molecular catalysts. Resins include linear, substantially linear, or heterogeneous polyethylene copolymers or homopolymers. LLDPEs contain less long chain branching than LDPEs and includes the substantially linear ethylene polymers which are further defined in U.S. Patent Nos. 5,272,236; 5,278,272; 5,582,923; and 5,733,155; the homogeneously branched linear ethylene polymer compositions such as those described in U.S. Patent No. 3,645,992; the heterogeneously branched ethylene polymers such as those prepared according to the process disclosed in U.S. Patent No.4,076,698; and / or blends thereof (such as those disclosed in U.S. Patent No. 3,914,342 or U.S. Patent No. 5,854,045). The LLDPEs can be made via gas- phase, solution-phase or slurry polymerization; or any combination thereof, using any type of reactor or reactor configuration known in the art.
[0021] The term “MDPE” refers to polyethylenes having densities from 0.926 g / cm3to 0.940 g / cm3. “MDPE” is typically made using chromium or Ziegler-Natta catalysts or using single-site catalysts including, but not limited to, bis-metallocene catalysts, constrained geometry catalysts, and molecular catalysts; and typically have a molecular weight distribution (“MWD”) > 2.5.
[0022] The term “HDPE” refers to polyethylenes having densities greater than 0.940 g / cm3and up to 0.970 g / cm3, which are generally prepared with Ziegler-Natta catalysts, chrome catalysts or single-site catalysts including, but not limited to, bis-metallocene catalysts and constrained geometry catalysts.
[0023] The term “ULDPE” refers to polyethylenes having densities of 0.880 g / cm3to 0.912 g / cm3, which are generally prepared with Ziegler-Natta catalysts, chrome catalysts, or single-site catalysts including, but not limited to, bis-metallocene catalysts and constrained geometry catalysts. "Polyethylene plastomers / elastomers" are substantially linear, or linear, ethylene / a-olefin copolymers containing homogeneous short-chain branching distributions comprising units derived from ethylene and units derived from at least one C3-C10 a-olefin comonomer, or at least one C4-C8 a-olefin comonomer, or at least one C6-C8 α-olefin comonomer. Polyethylene plastomers / elastomers have a density from 0.870 g / cm3, or 0.880 g / cm3, or 0.89085651-WO-PCT / DOW 85651 WO 7 g / cm3to 0.900 g / cm3, or 0.902 g / cm3, or 0.904 g / cm3, or 0.909 g / cm3, or 0.910 g / cm3, or 0.917 g / cm3. Non-limiting examples of polyethylene plastomers / elastomers include AFFINITY™ plastomers and elastomers (available from The Dow Chemical Company), EXACT Plastomers (available from ExxonMobil Chemical), TAFMER™ (available from Mitsui Chemicals), NEXLENE™ (available from SK Chemicals Co.), and LUCENE™ (available from LG Chemical Ltd.); and mixtures thereof.
[0024] “Blend”, “polymer blend” and like terms mean a composition of two or more polymers. Such a blend may or may not be miscible. Such a blend may or may not be phase separated. Such a blend may or may not contain one or more domain configurations, as determined from transmission electron spectroscopy, light scattering, x-ray scattering, and any other method known in the art. Blends are not laminates, but one or more layers of a laminate may contain a blend. Such blends can be prepared as dry blends, formed in situ (e.g., in a reactor), melt blends, or using other techniques known to those of skill in the art.
[0025] The terms “pre-consumer recycled polymer” and “post-industrial recycled polymer” (“PIR”) refer to polymers, including blends of polymers, recovered from pre-consumer material, as defined by ISO-14021. The generic term pre-consumer recycled polymer thus includes blends of polymers recovered from materials diverted from the waste stream during a manufacturing process. The generic term pre-consumer recycled polymer excludes the reutilization of materials, such as rework, regrind, or scrap, generated in a process and capable of being reclaimed within the same process that generated it.
[0026] The term “post-consumer recycled resin” or “post-consumer recycled polymer” (“PCR”), as used herein, refers to a polymeric material, including blends of polymers, recovered from materials previously used in a consumer or industry application, as defined by ISO-14021. The generic term post-consumer recycled resin thus includes blends of polymers recovered from materials generated by households or by commercial, industrial, and institutional facilities in their role as end-users of the material, which can no longer be used for its intended purpose. The generic term post-consumer recycled resin also includes blends of polymers recovered from returns of materials from the distribution chain. PCR resin is often collected from recycling programs and recycling plants. The PCR resin may include one or more of a polyethylene, a polypropylene, a polyester, a poly(vinyl chloride), a polystyrene, an acrylonitrile butadiene styrene, a polyamide,85651-WO-PCT / DOW 85651 WO 8 an ethylene vinyl alcohol, an ethylene vinyl acetate, or a poly-vinyl chloride. The PCR resin may include one or more contaminants. The contaminants may be the result of the polymeric material’s use prior to being repurposed for reuse. For example, contaminants may include paper, ink, food residue, or other recycled materials in addition to the polymer, which may result from the recycling process
[0027] PCR resin is distinct from virgin polymeric material. A virgin polymeric material does not include materials previously used in a consumer or industry application. Virgin polymeric material has not gone through consumer or industrial use, like a typical PCR resin. The physical, chemical, and flow properties of PCR resins differ when compared to virgin polymeric resin, which in turn can present challenges to incorporating PCR resin into formulations for commercial use.
[0028] The terms “comprising,” “including,” “having,” and their derivatives, are not intended to exclude the presence of any additional component, step or procedure, whether or not the same is specifically disclosed. In order to avoid any doubt, all compositions claimed through use of the term “comprising” may include any additional additive, adjuvant, or compound, whether polymeric or otherwise, unless stated to the contrary. In contrast, the term, “consisting essentially of’ excludes from the scope of any succeeding recitation any other component, step or procedure, excepting those that are not essential to operability. The term “consisting of’ excludes any component, step or procedure not specifically delineated or listed.
[0029] An objective of the present invention is to produce a first article from original components for use in a first application; and then subsequently, after the first article is used, the used first article can be reprocessed (i.e., the used first article can be subjected to, for example, a recycling process), as a whole, to form a second article from the reprocessed first article directly. The second article can then be used in another subsequent second application.
[0030] A further objective of the present invention is to process post-industrial recycled or post-consumer recycled material which comprises at least one polyolefin polymer and one or more adhering or coating auxiliaries into recycled articles.
[0031] The first article includes a combination of: (a) at least one polyolefin polymer, (b) one or more adhering or coating auxiliaries, and (c) at least one compatibilizer. It has been found85651-WO-PCT / DOW 85651 WO 9 that inclusion of the compatibilizer in the first article imparts a recyclability property to the first article; and thus, in some embodiments, the first article is recyclable and can be used to produce the second article for various other applications. Specifically, the adhering or coating auxiliaries are typically not chemically compatible with polyolefins and as a result, they appear in micron- to millimeter-sized gels in the PCR resins and films generated from PCR and PIR materials comprising adhering or coating auxiliaries. The articles and processes of the present disclosure address such undesirable gels with the inclusion of the compatibilizer to effectively integrate the adhering or coating auxiliaries from PCR and PIR materials with the remaining polyolefins to generate second articles for various other applications.
[0032] In some non-limiting embodiments, the first article of the present invention may include, for example, one or more of the following articles: a pellet, a film such as a monolayer or multilayer film, a multilayer laminate, a packaging product, and the like. In some non-limiting embodiments, the second article of the present invention may also include, for example, one or more of the following articles: a pellet, a film such as a monolayer or multilayer film, a multilayer laminate, a packaging product, and the like.
[0033] The polyolefin polymer, component (a), useful for making the first article of the present invention can include one or more polyolefins. The first article can be, for example, a polyolefin film. Generally, the polymeric portion of the film is comprised of at least 80 % of a polyolefin polymer in one embodiment, at least 85 % of a polyolefin polymer in another embodiment, and at least 90 % of a polyolefin polymer in still another embodiment. In one embodiment, the polyolefin polymer is at least one PE polymer. For example, the PE polymer, can include one or more of HDPE, LDPE, LLDPE, and mixtures thereof. The polyolefin film may be a monolayer or a multilayer film or may be an oriented film, oriented by machine direction orientation (MDO) or biaxial orientation processes. In another preferred embodiment, the polyolefin is polypropylene (PP), oriented PP (OPP), biaxially oriented PP (BOPP), and mixtures thereof.
[0034] The one or more adhering or coating auxiliaries, component (b), useful for making the first article of the present invention are provided as coating and / or adhesives in the formation of the first article. It is noted cured laminating adhesives and packaging coatings are referred to as “adhering or coating auxiliaries”, and grammatical variations thereof, in this disclosure.85651-WO-PCT / DOW 85651 WO 10 Specifically, production of laminates, packages, and other polymer film based structures which are typically utilized as post-consumer or post-industrial recycled polymers include adhesives to bind layers together and / or coatings to provide abrasion resistance, UV light protection, printable layers, or other desirable attribute. These adhesive and coatings are collectively referenced as adhering or coating auxiliaries.
[0035] The compatibilizer, component (c), useful for making the first article of the present invention with recyclability property in accordance with the standards detailed supra provides for integration of the adhering or coating auxiliaries during recycling. The compatibilizer provided as a component of the first article comprises virgin ethylene-based polymer. Further, the virgin ethylene-based polymer is the polymerized reaction product of ethylene. In one or more embodiments, the virgin ethylene-based polymer is the polymerized reaction product of ethylene copolymerized with one or more polar comonomers. The virgin ethylene-based polymer may additional or alternatively be the polymerized reaction product of ethylene grafted with one or more polar comonomers.
[0036] Having generally described the components of the first article having a recyclability property, embodiments of the first article and the various components will be provided in further detail.
[0037] As aforementioned, the present invention can comprise a wide variety of first articles such as films, laminates, or packages and the like. Therefore, as an illustration only of the present invention and not to be limited thereby, the present invention is described herein with reference to a preferred embodiment which is a monolayer or multilayer laminate structure, and more particularly, a multilayer laminate structure or a coated structure. It is, however, understood by one skilled in the art that many other articles can comprise the first article other than a laminate; and that the present invention is not limited thereto.
[0038] In some embodiments, the present invention includes, for example, a multilayer laminate structure; in other embodiments, the present invention includes an adhesive lamination process for manufacturing the multilayer laminate structure; and in still other embodiments, the present invention is directed to a packaging article made using the multilayer laminate structure. In each instance, the first article may additionally include one or more coatings on a surface layer.85651-WO-PCT / DOW 85651 WO 11
[0039] In one broad embodiment, the present invention includes a multilayer laminate structure as a first article which can be used for producing a laminated or coated packaging material that, in turn, can be recycled at the storefront for further processing. The multilayer laminate includes the combination of at least two polyolefin layer substrates adhered together by a layer of adhesive. For example, the multilayer laminate structure comprises: (i) at least a first polymer film layer comprising a first polyolefin polymer, such as a polyethylene (PE) film; (ii) at least a second polymer film layer comprising a second polyolefin polymer which can also be the same as the first polyolefin polymer or a different material; (iii) a layer of adhesive comprising one or more poly(vinyl acetate)-co-polyethylenes, polyesters, acrylics, or polyurethanes described above for bonding the first and second polyolefin film layers together; and (iv) at least one compatibilizer comprising virgin ethylene-based polymer, wherein the virgin ethylene-based polymer is the polymerized reaction product of ethylene optionally copolymerized and / or grafted with one or more polar comonomers; wherein the layer of adhesive is compatible with the first and second film layers; and wherein the layer of adhesive is disposed on the surface of at least one of the layers of the first film layer and the second film layer for binding the first film layer and the second film layer together. One or more other optional film layer substrates can be added to the above laminate structure with the adhesive added in-between multiple layers to produce a multi- layer laminate structure comprising more than two layers, if desired. Further, the laminate may further comprise a coating layer positioned on any of the film layers comprising one or more inorganic fillers, bio-derived tree resins and waxes, polypropylene, poly(vinyl acetate)-co- polyethylenes, polyesters, acrylics, or polyurethanes.
[0040] The first polymer film layer and the second polymer film layer, components (i) and (ii), used for making the multilayer laminate of the present disclosure can include one or more polyolefins. For example, each of the first polymer film layer and the second polymer film layer, can include one or more polyolefin layers such as HDPE, LDPE, LLDPE, MDO PE, BOPE, and mixtures thereof.
[0041] In one or more embodiments, the first polymer film layer can include, for example, a polyethylene film web which is bonded to the second polymer film layer through an adhesive. Similarly, in one or more embodiments, the second polymer film layer can include, for example, a polyethylene film web which is bonded to the first polymer film layer through an adhesive.85651-WO-PCT / DOW 85651 WO 12
[0042] In one or more embodiments, the first polymer film layer can include a multilayer film which is bonded to the second polymer film layer through an adhesive. Similarly, in one or more embodiments, the second polymer film layer can include a multilayer film which is bonded to the first polymer film layer through an adhesive.
[0043] In various embodiments, the adhesives compositions utilized in the first article of the present disclosure may be inorganic fillers, bio-derived tree resins and waxes, polypropylene, poly(vinyl acetate)-co-polyethylenes, polyesters, acrylics, polyurethane, and mixtures thereof. Example adhesives include acrylic based materials formed from an acrylic emulsion of acrylic monomers such as ethyl acrylate, methyl methacrylate, butyl acrylate, acrylic acid, methacrylic acid, incorporated with polypropylene glycol, and cured with isocyanate. In one or more preferred embodiments, the adhesive may be a polyurethane based adhesive composition. Generally, the adhesive of the present disclosure may encompass those useful in products such as fresh and frozen produce packaging, general snack packaging, and other consumer packaging.
[0044] The laminate structure of the present invention can include other optional layered substrates, component (v), in addition to the above component layers (i)-(iv). For example, substrates such as EVOH, PVDC, OPA, and mixtures thereof can be laminated (bonded) to the above first and second layers, if desired.
[0045] The compatibilizer, component (iv), provided within the laminate structure can impart improved recyclability to the laminate structure. When an article, for example a packaging article, is manufactured from the laminate structure containing the compatibilizer composition, the compatibilizer composition imparts the packaging article made from the recyclable laminate structure an acceptable recyclability property to allow the packaging article, after use, to be recycled.
[0046] The compatibilizer may be provided as a discrete layer within the laminate structure or alternatively may be integrated with the adhesive to form an adhesive compound which imparts the recyclability property. Alternatively, the at least one compatibilizer can be incorporated into the polyolefin layers through compounding.85651-WO-PCT / DOW 85651 WO 13
[0047] The compatibilizer comprises virgin ethylene-based polymer which is the polymerized reaction product of ethylene optionally copolymerized and / or grafted with one or more polar comonomers.
[0048] In one or more embodiments, the virgin ethylene-based polymer is grafted with maleic anhydride. Commercially available examples of the virgin ethylene-based polymer grafted with maleic anhydride include FUSABOND™ E528 (The Dow Chemical Company, Midland, Michigan).
[0049] In one or more embodiments, the ethylene-based polymer grafted with maleic anhydride has a density less than about 1.000 grams per cubic centimeter (g / cm3), or from about 0.86 g / cm3to about 1.000 g / cm3, as measured according to ASTM Method No. D792-91. Other density ranges may be from about 0.87 g / cm3to about 0.960 g / cm3, from about 0.87 g / cm3to about 0.950 g / cm3, from about 0.900 g / cm3to about 0.940 g / cm3from about 0.910 g / cm3to about 0.960 g / cm3, or from about 0.910 g / cm3to about 0.940 g / cm3.
[0050] In one or more embodiments, the ethylene-based polymer grafted with maleic anhydride may have a melt index (I2) of about 1 grams per 10 minutes (g / 10 min) to about 800 g / 10 min, from about 1 g / 10 min to about 100 g / 10 min, from about 1 g / 10 min to about 30 g / 10 min, from about 1 g / 10 min to about 15 g / 10 min, from about 1 g / 10 min to about 10 g / 10 min, or from about 1 g / 10 min to about 8 g / 10 min as determined in accordance with ASTM method D1238 at 190ºC and 2.16 kg.
[0051] In one or more further embodiments, the virgin ethylene-based polymer is the polymerized reaction product of ethylene, acrylate comonomer, maleic acid monoethyl ester, and optionally additional comonomers. In one or more embodiments the compatibilizer comprises a terpolymer of ethylene, alkyl acrylate, and glycidyl ester. In one or more embodiments where the compatibilizer comprises a terpolymer of ethylene, alkyl acrylate, and glycidyl ester, the alkyl acrylate comprises n-butyl acrylate (nBA), iso-butyl acrylate, methyl-acrylate, ethyl-acrylate, or combinations thereof. Further, in one or more embodiments where the compatibilizer comprises a terpolymer of ethylene, alkyl acrylate, and glycidyl ester, the glycidyl ester comprises glycidyl methacrylate (GMA). For example, in one or more embodiments, compatibilizer may comprise an ethylene copolymer in combination with n-butyl acrylate and glycidyl methacrylate. Commercially available examples of such compatibilizers representing the polymerized reaction85651-WO-PCT / DOW 85651 WO 14 product of ethylene, acrylate comonomer, and optionally additional comonomers include the ELVALOY™ copolymers from The Dow Chemical Company (Midland, Michigan).
[0052] In one or more embodiments, the terpolymer of ethylene, alkyl acrylate, and glycidyl ester has a density less than about 1.0 grams per cubic centimeter (g / cm3), or from about 0.9 g / cm3to about 1.0 g / cm3, as measured according to ASTM Method No. D792-91. Other density ranges may be from about 0.900 g / cm3to about 0.990 g / cm3, from about 0.900 g / cm3to about 0.980 g / cm3, from about 0.900 g / cm3to about 0.960 g / cm3, from about 0.920 g / cm3to about 1.000 g / cm3, from about 0.920 g / cm3to about 0.980 g / cm3, from about 0.920 g / cm3to about 0.960 g / cm3, or from about 0.930 g / cm3to about 0.950 g / cm3.
[0053] In one or more embodiments, the terpolymer of ethylene, alkyl acrylate, and glycidyl ester may have a melt index (I2) of about 1 grams per 10 minutes (g / 10 min) to about 85 g / 10 min, from about 1 g / 10 min to about 30 g / 10 min, from about 40 g / 10 min to about 80 g / 10 min, from about 1 g / 10 min to about 20 g / 10 min, from about 1 g / 10 min to about 15 g / 10 min, from about 5 g / 10 min to about 30 g / 10 min, from about 5 g / 10 min to about 20 g / 10 min, or from about 5 g / 10 min to about 18 g / 10 min as determined in accordance with ASTM method D1238 at 190ºC and 2.16 kg.
[0054] In one or more embodiments the compatibilizer may be provided in the first article at a concentration of 0.5 to 15 percent by weight (wt%). In various further embodiments, the compatibilizer may be provided in the first article at a concentration of 0.5 to 12 wt%, 2 to 15 wt%, 3 to 10 wt%, 1 to 8 wt%, 3 to 8 wt%, or 4 to 6 wt%. Similarly, the compatibilizer may be provided at 0.5 to 15 wt%, 1 to 12 wt%, 2 to 15 wt%, 2 to 10 wt%, 1 to 8 wt%, 2 to 8 wt%, or 3 to 6 wt% in the final blend for any compounding step for generation of second generation articles or films produced with the PCR polymer or PIR polymer according to the present step.
[0055] While embodiments have generally been described in the context of a laminate, a coated film is also within the scope of the present disclosure. Specifically, a film formed from a polyolefin polymer may be coated with the one or more adhering or coating auxiliaries to form a coating layer on a surface of the film. Accordingly, a coated film having a recyclability property is provided in one or more embodiments. The coated film includes (a) at least one first polymer film layer, the first polymer film layer comprising a first polyolefin polymer; (b) one or more adhering or coating auxiliaries comprising one or more components selected from poly(vinyl85651-WO-PCT / DOW 85651 WO 15 acetate)-co-polyethylenes, polyesters, acrylics, and polyurethane; and (c) at least one compatibilizer. The compatibilizer includes virgin ethylene-based polymer, wherein the virgin ethylene-based polymer is the polymerized reaction product of ethylene optionally copolymerized and / or grafted with one or more polar comonomers. Further, the one or more adhering or coating auxiliaries are provided as a coating layer on the surface of the first polymer film layer. The first polyolefin polymer forming the coated film may be in accordance with any of the various described embodiments with regards to the first polyolefin polymer and / or the second polyolefin polymer of the laminate having a recyclability property.
[0056] In general, the articles and laminate of the present invention, prior to recycling, can be used in a wide range of applications including, for example, packaging applications for manufacturing various packaging materials and products. For example, the laminate can be used for bulk packaging of food grains / pulses, packaging of seeds, packaging of lentils and cereals, packaging of fertilizer, packaging of oilseed, packaging of sugar, packaging of salt, packaging of pharmaceuticals, packaging of other food stuff, and personal care items such as bath salts, detergent pods and the like. The film may also be used as a wrapper for baby wipes, feminine hygiene products, cereal bars, protein bars, cheese, and confectionary products. The recycled materials of the present invention can be used to produce further packing materials as well as non- packaging materials.
[0057] One of the advantages of the articles and laminates in accordance with the present disclosure is that a used virgin article (first article) made from the laminate of the present disclosure can be reprocessed, that is, processed through a recycling process. After recycling, the recycled material from the previous virgin article can be used to make a subsequent recycled laminate, and in turn a recycled article (i.e., a second article), with properties and performances very close to the previous virgin article. One objective of the presently disclosed polymer structures is to produce a second article that performs as well as, or better than, the first article, that is the properties of the second article performs 100 % the same as, or greater than, the properties of the first article. At a minimum, the properties of the second article are maintained at a sufficient level of performance to provide a second article that is useful in another application.
[0058] For example, a new monolayer film structure (second article) made with recycled material from the recycled article (first article) can have properties that exhibits < 33 % decreased85651-WO-PCT / DOW 85651 WO 16 change in performance relative to a control film without any adhering or coating auxiliaries or compatibilizer added that is reprocessed the same way as the virgin article. In some embodiments, the new monolayer film structure (second article) can have properties that exhibits a decreased change in performance at <30% in one embodiment, < 25% in one embodiment, < 20 % in another embodiment, and < 15 % in still another embodiment. In some embodiments, the new monolayer film structure can have properties that exhibits a decreased change in performance in the range of from 0 % to < 33 % in one embodiment, 0.01 % to < 33 % in another embodiment, and from 0.1 % to < 33 % in still another embodiment. In some embodiments, the new monolayer film structure can have properties that exhibits a decreased change in performance in the range of from 0 % to < 25 % in one embodiment, 0.01 % to < 25 % in another embodiment, and from 0.1 % to < 25 % in still another embodiment. In some embodiments, the new monolayer film structure can have properties that exhibits a decreased change in performance in the range of from 0 % to < 10 % in one embodiment, 0.01 % to < 10 % in another embodiment, and from 0.1 % to < 10 % in still another embodiment.
[0059] In a general embodiment, the process for producing a reprocessed second article from, for example, a first packaging article (that is, the virgin article) comprises the steps of: (A) providing a first packaging article made from the laminate of the present disclosure; (B) fragmenting the packaging article from step (A) to produce a plurality of fragments of a predetermined size; (C) pelletizing the plurality of fragments from step (B) to form a plurality of pellets of a predetermined size; and (D) processing the pellets from step (C) to form a reprocessed second article. Accordingly, the compatibilizer is incorporated into the first packaging article allowing for direct recycling without addition of additional or alternative additive or reprocessing aids such as compatibilizer.
[0060] In further general embodiments, the process for producing a reprocessed second article from, for example, a first packaging article (that is, the virgin article) comprises the steps of: (A) providing a first packaging article made from a laminate comprising one or more adhering or coating auxiliaries as defined by the present disclosure; (B) fragmenting the packaging article from step (A) to produce a plurality of fragments of a predetermined size; (C) pelletizing the plurality of fragments from step (B) along with at least one compatibilizer in accordance with those of the present disclosure to form a plurality of pellets of a predetermined size; and (D) processing the pellets from step (C) to form a reprocessed second article. For example, the85651-WO-PCT / DOW 85651 WO 17 compatibilizer may be used in a masterbatch of polyethylene resin that is blended with the reclaimed flexible packages, that is the first packaging article, to produce the second article. It will further be appreciated that in lieu of the first packaging article, any polyolefin film or laminate comprising at least one polyolefin polymer and one or more adhering or coating auxiliaries in accordance with the present disclosure may be provided.
[0061] In some embodiments, a third article can be produced from the reprocessed second article made by the above general processes. For example, the third article can be selected from the group consisting of: pellets, monolayer or multilayer films, multilayer laminates, and packaging materials or products.
[0062] TEST METHODS
[0063] The test methods include the following:
[0064] Density (g / cm3)
[0065] To test density, samples are prepared and measured according to ASTM D792 at 190 ℃ and 2.16 kg for ethylene and 230 ℃ and 2.16 kg for propylene and reported in grams per cubic centimeter (g / cm3).
[0066] Melt Index (g / 10 min)
[0067] To test melt index, samples are prepared and measured according to ASTM D1238 and reported in grams per 10 minutes (g / 10 min).
[0068] Dart Impact (g)
[0069] To test the dart, samples are prepared and measured according to ASTM D1709 A and reported in grams (g).
[0070] Tear Strength (gram-force)
[0071] To test the tear strength, samples are prepared and measured according to ASTM D1922 and reported in gram-force.
[0072] Tensile Strength (MPa)85651-WO-PCT / DOW 85651 WO 18
[0073] To test the stress at break, samples are prepared and measured according to ASTM D638 and reported in MegaPascal (MPa).
[0074] Elongation (%)
[0075] To test the elongation at yield, samples are prepared and measured according to ASTM D882 and reported in percent elongation (%).
[0076] EXAMPLES
[0077] The following examples are presented to further illustrate the present invention in detail but are not to be construed as limiting the scope of the claims. Unless otherwise indicated, all parts and percentages are by weight.
[0078] Various materials used in the Inventive Examples (Inv. Ex.) and the Comparative Examples (Comp. Ex.), which follow, are described in Table I. Table I - Raw Materials85651-WO-PCT / DOW 85651 WO 19
[0079] Various materials used as the compatibilizer in the Inventive Examples (Inv. Ex.), which follow, are described in Table II. Table II - Compatibilizers
[0081] A sealant web film described in Table III, HDPE Film Structure was produced having seven layers with composition of each of the seven layers described in Tables III. The film was produced by using the following general process: The film was made on a seven layer blown film line (available from Hosokawa- Alpine). The line utilizes seven, 50 millimeter (mm) diameter, 30 L / D extruders that feed a 250 mm diameter spiral mandrel die with a 2 mm die gap. The output rate was 148 kilograms per hour (kg / hr) and the melt temperature ranged from 185 ℃ to 245 ℃. A 2.5 blow up ratio was used in blowing the film and the film was cooled with a single lip air ring and internal bubble cooling. The line speed was -17 meters per minute (m / min) and the film was corona treated to an average surface energy of 43 dynes / centimeter. Table III - HDPE Film Structure85651-WO-PCT / DOW 85651 WO 20
[0082] A first set of two of the HDPE films are laminated together with adhesive formed from MOR-Free™ L75-164 and MOR-Free™ C411 (MOR-Free™ 75-164 / C411) and a second set of two of the HDPE films are laminated together with adhesive formed from ADCOTE™ 577 and CR87-124 coreactant (ADCOTE™ 577 / 87-124) using the process “General Procedure for Film Lamination” described herein below. Both the MOR-Free™ 75-164 / C411 and the ADCOTE™ 577 / 87-124 are adhesive formulations commonly utilized for production of films in consumer good.
[0083] Each of the resulting composite film laminates are reprocessed by shredding the films, pelletizing the films, extruding / compounding the pellets, and forming a second film from the compounded pellets originating from each of the first composite film laminates using the procedures described herein below.
[0084] Subsequently, the second films are tested using the testing procedures described herein below with the results of the testing described in Tables VI and VII.
[0085] General Procedure for Film Lamination
[0086] Lamination is accomplished by using a Super - Combi 3000 series commercial laminator (available from Nordmeccanica). The laminator has a maximum film width of 1,320 mm and a minimum film width of 600 mm. Additionally, the laminator contains 2 modular85651-WO-PCT / DOW 85651 WO 21 coating decks: (1) a waterborne deck for waterborne lamination and (2) a Gravure deck for water- based and solvent-based adhesives / coatings. The laminator also contains 2 zone forced air dryers and a 7.5 kilowatt (KW) corona treater (available from Enercon Industries Corporation) for both a primary film and a secondary film. The maximum line speed of the laminator is 400 meters per minute (m / min) (or 1,312 feet per minute). All unwinds use a 76 mm or a 152 mm core and rewinds use only a 152-mm core. The laminator is capable of running most packing films such as polyester, oriented polypropylene, polyethylene, nylon, paper, foil (secondary only) and others. The HDPE films and the adhesives were run on the laminator with a target adhesive application of 1.6 grams per square meter (gsm) for the MOR-Free™ 75-164 / C411 samples and 2.9 gsm for the ADCOTE™ 577 / 87-124 samples utilizing the Gravure deck of the laminator. Upon completion of the lamination, the rolls of film were allowed to fully cure at room temperature (21±2 °C, 50% relative humidity) for 7 days.
[0087] General Procedure for Film Shredding / Pelletizing
[0088] Shredding and pelletizing are accomplished using an INTAREMA® 605 K pelletizer unit (available from EREMA North America, Inc., Ipswich, Massachusetts). The barrel zone of the pelletizer is run at 171 °C; and the pelletizer zone is run at 176 °C.
[0089] Fabrication Line
[0090] Monolayer blown films were produced via a Collin LabLine E30P, available from COLLIN Lab & Pilot Solutions GmbH, Maitenbeth, Germany. The line was comprised of three 25:1 L / D single screw extruders, equipped with grooved feed zones. The screw diameters were 25 mm for the inner layer, 30 mm for the core and 25 mm for the outer layer. The annular die was 60 mm in diameter and used a dual lip air ring cooling system. The film fabrication conditions were as follows: film thickness maintained at 50 μm (2.0 mil); blow up ratio (BUR) 2.5; die lip gap was set at 2 mm; blow up ratio (BUR) was 2.5 and draw down ratio (DDR) was 31.5, Frost line height (FLH) was 165 mm (6.5 inches); The output rate of approximately was 8.80 kilograms per hour. Melt temperature and die temperature were set at 215° C. The standard conditions and possible ranges of conditions are summarized in Table V.85651-WO-PCT / DOW 85651 WO 22 Table V - Blown Film Fabrication Conditions
[0091] Film Testing
[0092] Comparative Examples were prepared by fabricating recycled film with pellets generated from the laminated film and pellets generated from the HDPE film compounded at a 1:1 weight ratio. Comparative Example A was generated using the laminated film with MOR- Free™ 75-164 / C411 as the adhesive and Comparative Example B was generated using the laminated film with ADCOTE™ 577 / 87-124 as the adhesive.
[0093] The Inventive Examples were prepared by fabricating recycled film with pellets generated from the laminated film and pellets generated from the HDPE film compounded at a 1:1 weight ratio along with 5 wt.% of at least one compatibilizer. Inventive Examples 1 through 5 were generated using the laminated film with MOR-Free™ 75-164 / C411 along with one of the compatibilizers. Specifically, Inventive Example 1 includes 5 wt% of Compatibilizer 1, Inventive Example 2 includes 5 wt% of Compatibilizer 2, Inventive Example 3 includes 5 wt% of Compatibilizer 3, Inventive Example 4 includes 5 wt% of Compatibilizer 4, and Inventive Example 5 includes 5 wt% of Compatibilizer 5. Similarly, Inventive Examples 6 through 10 were generated using the laminated film with ADCOTE™ 577 / 87-124 along with one of the compatibilizers. Specifically, Inventive Example 6 includes 5 wt% of Compatibilizer 1, Inventive Example 7 includes 5 wt% of Compatibilizer 2, Inventive Example 8 includes 5 wt% of Compatibilizer 3, Inventive Example 8 includes 5 wt% of Compatibilizer 4, and Inventive Example 10 includes 5 wt% of Compatibilizer 5.
[0094] Control Film consisting of the HDPE film and containing no laminating adhesive was also prepared. The Control Film is the sample for which all laminated films are compared to.85651-WO-PCT / DOW 85651 WO 23
[0095] The films prepared in the Examples were tested for the following physical properties: Dart, Tear Strength, Elongation at Yield, and Tensile Strength. The tests were conducted as described in the following ASTM test methods: ASTM D1709 A was used to measure Drop Dart; ASTM D1922 was used to measure Tear Strength; ASTM D882 was used to measure Tensile Strength; and ASTM D822 was used to measure Elongation at Yield. The results for each of the Inventive Examples 1 through 5 and Comparative Example A are provided in Table VI (MOR-Free™ 75-164 / C411) and the results for each of the Inventive Examples 6 through 10 and Comparative Example B are provided in Table VII (ADCOTE™ 577 / 87-124). Table VI - MOR-Free™ 75-164 / C411 Laminated Film Physical PropertiesTable VII - ADCOTE™ 577 / 87-124 Laminated Film Physical Properties85651-WO-PCT / DOW 85651 WO 24
[0096] Tables VIII and IX provide the comparative results of testing films of the present disclosure (Inv. Ex.1-10) and the Comparative Examples (Comp. Ex. A and B). The comparison was calculated as the difference between the parameter value for the comparative or inventive example film and the control film divided by the parameter value for the control film. This metric shows the relative increase or decrease in the parameter value. A decrease of at most 33% is used as the criterion for recyclability. Table VIII - MOR-Free™ 75-164 / C411 Laminated Film Comparative PerformanceTable IX - ADCOTE™ 577 / 87-124 Laminated Film Comparative Performance
[0097] Results85651-WO-PCT / DOW 85651 WO 25
[0098] The results described in Tables VIII and IX show that inclusion of a compatibilizer in accordance with the present disclosure improved the mechanical performance and allowed the recycled polymer film to pass the “< 33 % decreased change in performance” test, for example, in all categories as set forth in Tables VIII and IX. For instance, the Dart performance is well within the performance boundaries with no inventive examples having a 33 % decreased change in performance relative to the performance of the control film. It has been demonstrated that inclusion of a variety of compatibilizer types in accordance with the present disclosure pass the recyclability test. This is in contrast to each of the Comparative Examples where one or more of the performance parameters demonstrated a decrease in excess of 33% relative to the control film. Accordingly, inclusion of a compatibilizer in accordance with the present disclosure allows for previously unrecyclable plastic structures to be recycled.
[0099] It will be apparent that modifications and variations are possible without departing from the scope of the disclosure defined in the appended claims. More specifically, although some aspects of the present disclosure are identified herein as preferred or particularly advantageous, it is contemplated that the present disclosure is not necessarily limited to these aspects.
Claims
85651-WO-PCT / DOW 85651 WO 26 CLAIMS 1. A first article having a recyclability property comprising: (a) at least one polyolefin polymer; (b) one or more adhering or coating auxiliaries; and (c) at least one compatibilizer, the compatibilizer comprising virgin ethylene-based polymer, wherein the virgin ethylene-based polymer is the polymerized reaction product of ethylene optionally copolymerized and / or grafted with one or more polar comonomers, wherein: the first article comprises 0.5 to 15 wt.% of the compatibilizer.
2. The first article of claim 1, wherein the adhering or coating auxiliaries are selected from coatings and adhesives comprising one or more poly(vinyl acetate)-co-polyethylenes, polyesters, acrylics, or polyurethanes.
3. The first article of claim 1, wherein the one or more adhering or coating auxiliaries comprises a polyurethane based adhesive composition.
4. The first article of claim 1, wherein the one or more adhering or coating auxiliaries form a coating layer on a surface of a film formed from the polyolefin polymer, the coating layer comprising one or more inorganic fillers, bio-derived tree resins and waxes, polypropylene, poly(vinyl acetate)-co-polyethylenes, polyesters, acrylics, or polyurethanes.
5. The first article any one of claims 1 to 4, wherein the virgin ethylene-based polymer is grafted with maleic anhydride.
6. The first article of any one of claims 1 to 5, wherein the virgin ethylene-based polymer is the polymerized reaction product of ethylene, acrylate comonomer, and optionally additional comonomers.
7. The first article of any one of claims 1 to 6, wherein the first article comprises 0.5 to 6 wt.% of the compatibilizer.85651-WO-PCT / DOW 85651 WO 27 8. The first article of any of claims 1 to 7, wherein the recyclability property of the first article is such that when the first article is reprocessed into a second article comprising a single layer blown film with a film thickness of 2 mil (50 μm), the second article exhibits less than a 33 percent decrease in performance compared to a control article reprocessed the same way as the first article but formed from an article matching the composition of the first article without the one or more adhering or coating auxiliaries and the compatibilizer.
9. A laminate having a recyclability property comprising: (a) at least one first polymer film layer, the first polymer film layer comprising a first polyolefin polymer; (b) at least one second polymer film layer, the second polymer film layer comprising a second polyolefin polymer; (c) one or more adhesives, the adhesives comprising one or more inorganic fillers, bio- derived tree resins and waxes, polypropylene, poly(vinyl acetate)-co-polyethylenes, polyesters, acrylics, or polyurethanes; and (d) at least one compatibilizer, the compatibilizer comprising virgin ethylene-based polymer, wherein the virgin ethylene-based polymer is the polymerized reaction product of ethylene optionally copolymerized and / or grafted with one or more polar comonomers, wherein: the one or more adhesives are compatible with the at least one first polymer film layer and the at least one second polymer film layer, and the layer of the one or more adhesives is disposed on the surface of at least one of the layers of the first polymer film layer and the second polymer film layer for binding the first polymer film layer and the second polymer film layer together.
10. The laminate of claim 9, wherein the laminate further comprises a coating layer, the coating layer comprising one or more components selected from poly(vinyl acetate)-co- polyethylenes, polyesters, acrylics, and polyurethane.
11. The laminate of claim 9 or 10, wherein the one or more adhesives is a polyurethane based adhesive composition.85651-WO-PCT / DOW 85651 WO 28 12. The laminate of any of claims 9 to 11, wherein at least one of the first polymer film layer and the second polymer film layer comprise polyethylene PCR or PIR material.
13. The laminate of any of claims 9 to 12, wherein the first polymer film layer and the second polymer film layer comprise multilayer films.
14. A process for recycling a polyolefin film or laminate comprising: (A) providing a polyolefin film or laminate, wherein: the polyolefin film or laminate comprises at least one polyolefin polymer and one or more adhering or coating auxiliaries, and the polyolefin film or laminate is a PCR or PIR film or laminate; (B) fragmenting the polyolefin film or laminate from step (A) to produce a plurality of fragments of a predetermined size; (C) pelletizing the plurality of fragments from step (B) along with at least one compatibilizer to form a plurality of pellets of a predetermined size, wherein the compatibilizer comprises virgin ethylene-based polymer which is the polymerized reaction product of ethylene copolymerized and / or grafted with one or more polar comonomers.
15. The process of claim 14, wherein the compatibilizer is provided as a component of the polyolefin film or laminate.
Citation Information
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