Polyolefin composition comprising polypropylene polymers and a blend of a plastic material comprising polypropylene and polyethylene

Abstract

The present invention refers to a polyolefin composition comprising a) 55-98 wt% (based on the overall weight of the polyolefin composition) of a blend of plastic material comprising polypropylene and polyethylene in a ratio between 3:7 and 49.5:1 with a content of limonene as determined using solid phase microextraction (HS-SPME-GC-MS) of 0.1 ppm to 100 ppm;, b) 2-45 wt% (based on the overall weight of the polyolefin composition) of at least one heterophasic polypropylene copolymer (PPHeco) comprising a propylene homopolymer matrix and an elastomer phase dispersed therein with a melt flow rate MFR2 (230°C, 2.16 kg, measured according to ISO 1133) in the range of 1.0 to 25.0 g / 10 min; and c) optionally further additives, wherein the sum of all ingredients always adds up to 100 wt%.

Description

[0001] Polyolefin composition comprising polypropylene polymers and a blend of a plastic material comprising polypropylene and polyethylene

[0002] The invention relates to a polyolefin composition comprising at least one heterophasic polypropylene copolymer and a blend of a plastic material comprising polypropylene and polyethylene, in particular a blend of a recycled plastic material, to an article comprising the polyolefin composition and a process for preparing such a polyolefin composition.

[0003] Description

[0004] Polyolefins, in particular polyethylene and polypropylene are increasingly consumed in large amounts in a wide range of applications, including packaging for food and other goods, fibers, automotive components, and a great variety of manufactured articles. Taking into account the huge amount of waste collected compared to the amount of waste recycled back into the stream, there is still a great potential for intelligent reuse of plastic waste streams and for mechanical recycling of plastic wastes.

[0005] One major trend in the field of polyolefins is the use of recycled materials, which are derived from a wide variety of sources. Durable goods streams such as those derived from yellow bags, yellow bins, community collections, waste electrical equipment (WEE) or end-of-life vehicles (ELV) contain a wide variety of plastics. These materials can be processed to recover acrylonitrile-butadiene-styrene (ABS), high impact polystyrene (HIPS), polypropylene (PP) and polyethylene (PE) plastics. Separation can be carried out using density separation in water and then further separation based on fluorescence, near infrared absorption or raman fluorescence. However, it is commonly quite difficult to obtain either pure recycled polypropylene or pure recycled polyethylene.

[0006] Generally, recycled quantities of polypropylene on the market are mixtures of both polypropylene (PP) and polyethylene (PE), this is especially true for post-consumer waste streams. Moreover, commercial recyclates from post-consumer waste sources are conventionally cross-contaminated with non-polyolefin materials such as polyethylene terephthalate, polyamide, polystyrene or non-polymeric substances like wood, paper, glass or aluminum. These cross-contaminations drastically limit final applications of recycling streams such that no profitable final uses remain. Polyolefinic recycling materials, especially from postconsumer waste streams, are a mixture of PE and PP. The better the quality of the recyclate is, the less available it is and the more expensive it is. The quality issue in recyclates compared to the virgin ones can be to some extent overcome by mixing the recyclates with virgin polymers.

[0007] Compositions comprising virgin polymers (i.e. polymers used for the first time) and recycled mixed plastics have been studied.

[0008] EP 0 575 465 B1 covers a polymer blend composition comprising (a) 30 - 70 wt% of low melting polymer comprising an ethylene / a-olefin copolymer having a density of from 0.88 - 0.915 g / cm3, an MFR of 1 .5 - 7.5 dg / min, a molecular weight distribution no greater than 3.5, a composition distribution breadth index greater than 70 percent and an essentially single melting point in the range of 60 °C to 115 °C measured as a DSC peak Tm; and (b) 70 - 30 wt% of a propylene based polymer having from 88 to 100 mole percent propylene and from 12 to 0 mole percent of an alpha-olefin other than propylene.

[0009] US 5,266,392 A claims a polyethylene / polypropylene blend, comprising > 50 wt% of crystalline polypropylene; at least about 10 wt% of linear low density polyethylene having a density of about 0.915 to about 0.94 dispersed in a matrix of said polypropylene; and an amount of an ethylene / alpha-olefin plastomer compatibilizer having an alpha-olefin content of from ~5 - ~25 mol%, a melt index of above about 50 dg / min, a weight average molecular weight between about 5000 and about 50,000, a density of from about 0.88 about 0.90 g / cm3and an X-ray crystallinity of at least 10%. This covers the use of plastomers as compatibilizers in a very general way, including of course recycling. Only rather low and rather high densities are excluded for the plastomer, but pure HDPE is also excluded.

[0010] WO 2015 / 169690 A1 refers to polypropylene-polyethylene blends comprising (A) 75 - 90 wt% of a blend of (A-1) 30 - 70 wt% of polypropylene and (A-2) 70 - 30 wt% of polyethylene and (B) 10 - 25 wt % of a compatibilizer being a heterophasic polyolefin composition comprising (B-l) 55 - 90 wt% of a polypropylene with an MFR2 between 1.0 and 300 g / 10 min (according to ISO 1133 at 230°C at a load of 2.16 kg) and (B-2) 45 - 10 wt% of a copolymer of ethylene and propylene or C4 to C10 alpha olefin with a glass transition temperature Tg (measured with DMTA) of below -25°C and an intrinsic viscosity (measured in decalin at 135°C) of at least 3.0 dl / g, whereby the blend has (i) a Charpy Notched Impact Strength (according to ISO 179-leA, measured at 23 °C) of at least 2% higher than for the same blend without the compatibilizer (B) and at the same time (ii) a Flexural Modulus (according to ISO 178) of at least 3% higher than for the same blend without the compatibilizer (B) and additionally (iii) a heat deflection resistance (determined with DMTA) expressed by the temperature at which the storage modulus G' of 40 MPa is reached (T(G' = 40 MPa)) which is at least 4°C higher than for the same blend without the compatibilizer (B).

[0011] EP 3 165 473 A1 relates to polyolefin compositions comprising a blend (A) of recycled polypropylene and recycled polyethylene, a polypropylene having an MFR of not lower than 50 g / 10 min, and a compatibilizer being a heterophasic polyolefin composition, wherein the whole composition has a MFR of higher than 25 g / 10 min.

[0012] WO 2020 / 070176 A1 relates to polyolefin compositions which comprise recycled polyolefins and which are suitable for higher value products. The composition comprises a propylene homopolymer with an MFR of at least 400 g / 10 min.

[0013] WO2021 / 032458 A1 and WO2021 / 144404 A1 disclose polypropylene-polyethylene blends comprising a component A) being a recyclate blend and a component B) being a virgin heterophasic polypropylene copolymer. However, the polypropylene-polyethylene blends have a rather low tensile modulus and / or melt flow rate making them not suitable for certain applications.

[0014] US 2022 / 0025150 A1 discloses a polyolefin composition comprising 80-97 wt% recyclate Blend A and 3-20 wt% of compatibilizer comprising a random polypropylene copolymer matrix phase with elastomer phase dispersed therein. Thus, the heterophasic copolymer described herein consists of a random polypropylene matrix which results (due to the C2 content in the matrix), in poor mechanical properties, such as low stiffness as indicated by the low flex modulus between 300 and 600 MPa.

[0015] However, the known polymer compositions comprising recycled materials are not suited for a high-end market, rather the presently available recyclate compositions target low end applications such as crates, flower pots and benches etc. The presently available recyclate compositions cannot compete with virgin materials due to their mechanical properties.

[0016] In order to serve a high-end market e.g. for high flow applications and to compete with virgin materials (in particular in the area of non-food and non-health care products), certain adjustments need to be made. Currently available recyclates are facing main problems in composition (such as fluctuation in PP and PE content), in consistency (in terms of flow properties), in their property profile (poor stiffness-impact balance), and in cross-contamination (such as non-polyolefinic components, inorganic materials such as aluminum or paper) but also in colour and odour.

[0017] Thus, it was an object of the present invention to provide a polyolefin composition comprising polyolefin material recovered from waste plastic material without the disadvantages of the polymer compositions according to the prior art. In particular, a compound solution of a virgin material in combination with a recyclate is of an urgent need to balance out the above mentioned issues and to serve advanced material products for the market.

[0018] This object has been solved by providing a polyolefin composition comprising: a) 55-98 wt% (based on the overall weight of the polyolefin composition) of a blend of a plastic material comprising polypropylene and polyethylene in a ratio between 3:7 and 49.5:1 with a limonene content between 0.1 and 100 ppm, b) 2-45 wt% (based on the overall weight of the polyolefin composition) of at least one heterophasic polypropylene copolymer (PPHeco) comprising a propylene homopolymer matrix and an elastomer phase dispersed therein with a melt flow rate MFR2 (230°C, 2.16 kg, measured according to ISO 1133) in the range of 1.0 to 25.0 g / 10 min; and c) optionally further additives, wherein the sum of all ingredients always adds up to 100 wt%,

[0019] The present polyolefin composition combines both, polypropylene I polyethylene blend and a virgin material to compensate for the variations / composition issues in the polypropylene I polyethylene blend, in particular in a polypropylene / polyethylene recyclate blend recovered from a waste plastic material derived from post-consumer and / or post-industrial waste. By providing polyolefin compositions with combining high impact, melt flow and tensile modulus customer needs can be met. Furthermore, by using a recyclate material recycling quotes can be fulfilled, and waste can be reduced.

[0020] As shown in detail below, the present polyolefin composition is characterized by a balanced property profile that is only based on recyclate and virgin copolymers. The use of the specific virgin heterophasic copolymers boost the toughness, puncture energy and impact performance of the recyclate. At the same time stiffness and viscosity of the recyclate containing composition (two important properties for customers) is not hampered. The balanced compound properties make the present polyolefin composition interesting for many engineering applications. It was in particular surprising that a polyolefin composition comprising a high amount of recyclate of over 50 wt% and up to 98 wt% and a rather low amount of virgin heterophasic copolymer as impact modifier of minimum 2 wt% and up to 45 wt% a good property profile with a good toughness could be provided.

[0021] Thus, the present polyolefin composition combines virgin high flow heterophasic polypropylene material as impact booster for the recycled PP / PE material. This allows for the use of the polyolefin composition with a high amount of recycled material for current applications in the field of caps and closures and packaging like lids, in particular thin wall packaging applications.

[0022] It is to be understood that the present polyolefin composition does not contain talc (except the amounts present in the recyclate), glass fibers, rubber or any other solid material. It is further to be understood that the present polyolefin composition preferably does not contain or comprise any elastomer and polypropylene homopolymer except as minor residues in the recyclate material.

[0023] For the purposes of the present description and of the subsequent claims, the term “recycled” is used to indicate that the material is recovered from post-consumer waste and / or postindustrial waste. Namely, post-consumer waste refers to objects having completed at least a first use cycle (or life cycle), i.e. having already served their first purpose and been through the hands of a consumer; while post-industrial waste refers to the manufacturing scrap which does normally not reach a consumer. In the gist of the present invention “recycled polymers” may also comprise up to 17 wt%, preferably up to 3 wt%, more preferably up to 1 wt% and even more preferably up to 0.1 wt% based on the overall weight of the recycled polymer of other components originating from the first use. Type and amount of these components influence the physical properties of the recycled polymer. The physical properties given below refer to the main component of the recycled polymer.

[0024] As described also further below, typical other components originating from the first use are thermoplastic polymers, like polystyrene and PA 6, talc, chalk, ink, wood, paper, limonene and fatty acids. The content of polystyrene (PS) and polyamide 6 (PA 6) in recycled polymers can be determined by Fourier Transform Infrared Spectroscopy (FTIR) and the content of talc, chalk, wood and paper may be measured by Thermogravimetric Analysis (TGA). The term “virgin” denotes the newly produced materials and / or objects prior to first use and not being recycled. In case that the origin of the polymer is not explicitly mentioned the polymer is a “virgin” polymer.

[0025] The term ’’Xylene Solubles” refers to the percentage of soluble species in homo- and copolymers of polypropylene. Its value correlates to the R21 value and to the amorphous content of the polymer. For polypropylene homopolymers, R21 is a measure of tactility parameters like stiffness and hardness. For polypropylene copolymers, R21 additionally corresponds to comonomer related parameters such as transparency and gloss. Its measurement is widely used to control the polymerization process and to determine the physical properties of final products for Quality Control. Historically the xylene soluble content (ISO 16152, ASTM 5492) has been measured by extraction.

[0026] The total amount of virgin heterophasic polypropylene polymers used in the present polyolefin composition may add up to a range between 5-42 wt%, preferably between 10-40 wt%, more preferably between 20-40 wt% (based on the overall weight of the polymer composition).

[0027] The amount of the blend comprising polypropylene and polyethylene in a ratio between 3 : 7 and 49.5 :1 , preferably 3:7 and 15:1 , such as a blend of recycled plastic material comprising polypropylene and polyethylene which is recovered from a waste plastic material derived from post-consumer and / or post-industrial waste, used in the present polyolefin composition may be in a range between 58-95 wt%, preferably between 60-90 wt%, more preferably between 60-80 wt% (based on the overall weight of the polymer composition).

[0028] Thus, in an embodiment the polyolefin composition comprises: a) 58-95 wt%, preferably 60-90 wt%, preferably 60-80 wt% (based on the overall weight of the polyolefin composition) of the blend of plastic material comprising polypropylene and polyethylene with a limonene content between 0.1 and 100 ppm, b) 5-42 wt%, preferably 10-40 wt%, more preferably 20-40 wt% (based on the overall weight of the polyolefin composition) of the at least one heterophasic polypropylene copolymer (PPHeco) comprising a propylene homopolymer matrix and an elastomer phase dispersed therein; and optionally further additives, wherein the sum of all ingredients always adds up to 100 wt%. A preferred polyolefin composition comprises a) 60-80 wt% (based on the overall weight of the polyolefin composition) of the blend of plastic material comprising polypropylene and polyethylene with a limonene content between 0.1 and 100 ppm, b) 20-40 wt% (based on the overall weight of the polyolefin composition) of the at least one heterophasic polypropylene copolymer (PPHeco) comprising a propylene homopolymer matrix and an elastomer phase dispersed therein; and optionally further additives, wherein the sum of all ingredients always adds up to 100 wt%,

[0029] It is to be understood that the amounts of heterophasic propylene copolymer (PPHECO) and blend of recycled material are always complementary to each other. For example, the composition may comprise in one embodiment 10 wt% heterophasic propylene copolymer (PPHECO) and 90 wt% polypropylene recyclate or 20 wt% heterophasic propylene copolymer (PPHECO) and 80 wt% polypropylene recyclate, or 40 wt% heterophasic propylene copolymer (PPHECO) and 60 wt% polypropylene recyclate or anything in between.

[0030] In preferred embodiments the present polyolefin composition may comprise

[0031] - 2 wt% heterophasic propylene copolymer (PPHECO) and 98 wt% polypropylene recyclate;

[0032] - 5 wt% heterophasic propylene copolymer (PPHECO) and 95 wt% polypropylene recyclate;

[0033] - 10 wt% heterophasic propylene copolymer (PPHECO) and 90 wt% polypropylene recyclate;

[0034] - 15 wt% heterophasic propylene copolymer (PPHECO) and 85 wt% polypropylene recyclate;

[0035] - 20 wt% heterophasic propylene copolymer (PPHECO) and 80 wt% polypropylene recyclate;

[0036] - 25 wt% heterophasic propylene copolymer (PPHECO) and 75 wt% polypropylene recyclate

[0037] - 30 wt% heterophasic propylene copolymer (PPHECO) and 70 wt% polypropylene recyclate.

[0038] - 35 wt% heterophasic propylene copolymer (PPHECO) and 65 wt% polypropylene recyclate

[0039] - 40 wt% heterophasic propylene copolymer (PPHECO) and 60 wt% polypropylene recyclate. More specifically preferred embodiments will be described further below.

[0040] The composition according to the invention preferably shows a superior balance of properties in regard of flowability, as can be seen from the melt flow rate, impact properties and especially mechanical properties, such as in in regard of the tensile properties.

[0041] The present polyolefin composition may have one or more, preferably all of the properties as described in the following.

[0042] In an embodiment, the present polyolefin composition has an impact strength (ISO179, Charpy 1eA +23°C) of at least 6.0 kJ / m2, preferably at least 6.5 kJ / m2, more preferably at least 7.0 kJ / m2, in particular in a range between 6.0 and 20.0 kJ / m2, more in particular between 6.5 and 18.0 kJ / m2, even more in particular between 7.0 and 15.0 kJ / m2, and most in particular between 7.5 and 12.0 kJ / m2.

[0043] Still further, the composition preferably has a Charpy notched impact strength at -20°C of from 2.0 to 10.0 kJ / m2, preferably from 2.5 to 7.5 kJ / m2, determined according to ISO 179-1 / 1eA at 23°C.

[0044] In another embodiment, the present polyolefin composition has a melt flow rate MFR2 (230°C, 2.16 kg, measured according to ISO 1133-1) of at least 8.0 g / 10min, preferably of at least 10.0 g / 10min, more preferably of at last 12.0 g / 10 min, in particular in a range between 8.0 and 30.0 g / 10 min, preferably between 10.0 and 25.0 g / 10min, more preferably between 12.0 and 20.0 g / 10 min.

[0045] In still a further embodiment, the present polyolefin composition has a puncture energy (ISO 6603-2, 23°C) of at least 1.5 J, preferably of at least 2.0 J, more preferably of at least 3.0 J, even more preferably of at least 5.0 J, particular in a range between 1.5 and 25.0 J, more in particular in a range between 2.0 and 20.0 J, even more particular in a range between 3.0 and 18.0 J. Further, the composition preferably has a puncture energy of from 0.5 to 10.0 J, more preferably from 0.6 to7.0 J, more preferably from 0.8 to 6.0 J when determined in the instrumented puncture test according to ISO 6603-2 at -30 °C.

[0046] In another embodiment, the present polyolefin composition has a tensile strain at break (ISO 527-2, 23°C) of at least 15.0 %, preferably of at least 20.0 %, more preferably of at least 25.0 %, even more preferably of at least 30.0 %, particular in a range between 15.0 and 120.0 % , more in particular in a range between 20.0 and 100.0 %, even more particular in a range between 25.0 and 90.0 %, still more particular in a range between 30.0 and 80.0 %.

[0047] In still another embodiment, the present polyolefin composition has a tensile modulus (ISO 527-2, 23°C) of at least 1100 MPa, preferably of at least 1150 MPa, more preferably of at least 1200 MPa, particular in a range between 1100 MPa and 1500 MPa , more in particular in a range between 1100 MPa and 1300 MPa.

[0048] In a preferred embodiment, the present polyolefin composition may have one or more, preferably all of the following properties: an impact strength (ISO179, Charpy 1eA +23°C) in a range between 6.0 and 20.0 kJ / m2, more in particular between 6.5 and 18.0 kJ / m2, even more in particular between 7.0 and 15.0 kJ / m2, and most in particular between 7.5 and 12.0 kJ / m2, a melt flow rate MFR2 (230°C, 2.16 kg, measured according to ISO 1133-1) in a range between 8.0 and 30.0 g / 10 min, preferably between 10.0 and 25.0 g / 10min, more preferably between 12.0 and 20.0 g / 10 min, a puncture energy (ISO 6603-2, 23°C) in a range between 1.5 and 25.0 J, more in particular in a range between 2.0 and 20.0 J, even more particular in a range between 3.0 and 18.0 J, a tensile strain at break (ISO 527-2, 23°C) in a range between 15.0 and 120.0 % , more in particular in a range between 20.0 and 100.0 %, even more particular in a range between 25.0 and 90.0 %, still more particular in a range between 30.0 and 80.0 %, a tensile modulus (ISO 527-2, 23°C) in a range between 1100 MPa and 1500 MPa , more in particular in a range between 1100 MPa and 1300 MPa.

[0049] Heterophasic polypropylene copolymers comprise as polymer components a polypropylene matrix (M) and an elastomeric copolymer (E). In the present case, the polypropylene matrix (M) is a propylene homopolymer,. The elastomeric copolymer (E) comprises units derived from propylene and ethylene and / or C4 to C20 alpha-olefins, more preferably from ethylene and / or C4 to C10 alpha-olefins and most preferably from ethylene, C4, C6 and / or C8 alpha-olefins, e.g. ethylene and, optionally, units derived from a conjugated diene.

[0050] The heterophasic propylene copolymer (PPHeco) used in the present polyolefin composition is a virgin polymer.

[0051] The at least one heterophasic polypropylene copolymer may have a melt flow rate MFR2 (230°C, 2.16 kg, measured according to ISO 1133) in the range of 2.0 to 20.0 g / 10 min, preferably in the range of 3.0 to 15.0 g / 10 min, more preferably in the range of 5.0 to 11.0 g / 10 min.

[0052] Furthermore, the at least one heterophasic polypropylene copolymer may have a xylene soluble content (XCS) determined according to ISO 16152 based on the overall weight of heterophasic polypropylene copolymer in the range of 15.0 to 40.0 wt%; preferably in the range of 20.0 to 35.0 wt%, more preferably in the range of 20.0 to 32.0 wt%.

[0053] Even further, the at least one heterophasic polypropylene copolymer may have a total C2 content in the range of 5.0 to 30.0 wt%, preferably in the range of 6.0 to 25.0 wt%, more preferably in the range of 8.0 to 20.0 wt%, as determined by FT-IR spectroscopy calibrated by quantitative13C-NMR spectroscopy.

[0054] It is to be understood that the present polyolefin composition may comprise not only one, but two or more virgin heterophasic polypropylene copolymers.

[0055] Preferred heterophasic polypropylene copolymers are described now in more detail.

[0056] The at least one heterophasic polypropylene copolymer (PPHeco-1) may have one or more, preferably all of the following properties: a melt flow rate MFR2 (230°C, 2.16 kg, measured according to ISO 1133) in the range of 1.0 to 10.0 g / 10 min, preferably of 2.0 to 8.0 g / 10 min, more preferably of 4.0 to 6.0 g / 10 min, a xylene soluble content (XCS) determined according to ISO 16152 in the range of 20.0 to 30.0 wt%, preferably in the range of 20.0 to 27.0 wt%, more preferably in the range of 20.0 to 24.0 wt%, a total 02 content in the range of 5.0 to 15.0 wt%, preferably in the range of 6.0 to 10.0 wt%, more preferably in the range of 7.0 to 8.0 wt%, as determined by FT-IR spectroscopy calibrated by quantitative13C-NMR spectroscopy.

[0057] The at least one heterophasic polypropylene copolymer (PPHeco-1) may have further one or more, preferably all of the following properties: a soluble fraction (SF) content determined according to CRYSTEX QC analysis in the range from 12.0 wt.-% to 32.0 wt.-%, preferably from 17.0 to 27.0 wt.-%, more preferably from 19.5 to 24.5 wt.-%; an ethylene content of said soluble fraction C2(SF), as determined by FT-IR spectroscopy calibrated by quantitative13C-NMR spectroscopy, in the range from 10.0 to 40.0 wt.-%, preferably from 15.0 to 30.0 wt.-%, more preferably from 18.0 to 28.0 wt.-%; and an intrinsic viscosity of said soluble fraction iV(SF), as measured in decalin according to DIN ISO 1628 / 1 at 135°C, of more than 4.5 dl / g to 12.0 dl / g, preferably of 5.0 to 11.0 dl / g, more preferably of 6.0 to 9.0 dl / g.

[0058] The at least one heterophasic polypropylene copolymer (PPHeco-1) preferably has one or more, preferably all of the following properties: a crystalline fraction (CF) content determined according to CRYSTEX QC analysis in the range from 68.0 to 88.0 wt.-%, more preferably 73.0 to 83.0 wt.-%, still more preferably 75.5 to 80.5 wt.-%; and / or an ethylene content in said crystalline fraction C2(CF), as determined by FT-IR spectroscopy calibrated by quantitative13C-NMR spectroscopy, of 0.5 to 10.0 wt.-%, preferably of 1.0 to 9.0 wt.-%, more preferably of 1.5 to 5.0 wt.-%; and / or an intrinsic viscosity of said crystalline fraction iV(CF), as measured in decalin according to DIN ISO 1628 / 1 at 135°C of 1.5 to 5.0 dl / g, preferably of 2.0 to 4.0 dl / g, more preferably of 2.4 to 3.4 dl / g; and / or a ratio of the intrinsic viscosities of the soluble fraction and crystalline fraction (iV(SF) / iV(CF)) of 2.5 to 4.5, preferably of 2.8 to 4.0, more preferably of 3.1 to 3.9; and / or a ratio of the ethylene contents of the soluble fraction and crystalline fraction (C2(SF) / C2(CF)) of 5.0 to 20.0, more preferably in the range of from 6.0 to 15.0, still more preferably in the range of from 7.0 to 9.0; and / or a total content of units derived from ethylene (C2) of 3.0 to 20.0 wt.-%, preferably of 4.0 to 18.0 wt.-%, more preferably of 6.0 to 11.0 wt.-%, as determined by FT-IR spectroscopy calibrated by quantitative13C-NMR spectroscopy.

[0059] The at least one heterophasic polypropylene copolymer (PPHeco-1) also preferably has one or more, preferably all of the following properties: an intrinsic viscosity of said XCS fraction iV(XCS), as measured in decalin according to DIN ISO 1628 / 1 at 135°C, of 2.5 dl / g to 8.5 dl / g, preferably of 3.0 to 8.0 dl / g, more preferably of 3.5 to 7.5 dl / g.

[0060] Further, the at least one heterophasic polypropylene copolymer (PPHeco-1) preferably has one or more, more preferably all, of the following properties: a melt temperature Tm of from 155 to 175°C, preferably from 157 to 172°C, more preferably from 160 to 170°C; and / or a crystallization temperature Tc of from 105 to 125°C, preferably from 107 to 122°C, more preferably from 110 to 120°C.

[0061] The heterophasic polypropylene copolymer (PPHeco-1) may have a Charpy Notched Impact Strength (NIS) measured according to ISO 179-1 eA at 23°C of at least 40 kJ / m2, preferably at least 45 kJ / m2, like in the range of 40 to 60 kJ / m2, preferably in the range of 45 to 55 kJ / m2, like 48 to 50 kJ / m2.

[0062] The heterophasic polypropylene copolymer (PPHeco-1) may have a flexural modulus measured according to ISO 178 of at least 800 MPa, preferably at least 1000 MPa, like in the range of 800 to 1500 MPa, preferably in the range of 1000 to 1300 MPa, like 1100 to 1200 MPa.

[0063] The heterophasic polypropylene copolymer (PPHeco-1) is known in the art and commercially available for example from Borealis AG.

[0064] The at least one heterophasic polypropylene copolymer (PPHeco-2) may have one or more, preferably all of the following properties:

[0065] - a melt flow rate MFR2 (230°C, 2.16 kg, measured according to ISO 1133) in the range of 5.0 to 20.0 g / 10 min, preferably of 8.0 to 15.0 g / 10 min, more preferably of 10.0 to 12.0 g / 10 min;

[0066] - a xylene soluble content (XCS) determined according to ISO 16152 in the range of 20.0 to 35.0 wt%, preferably in the range of 25.0 to 32.0 wt%, more preferably in the range of 27.0 to 30.0 wt%,

[0067] - a total C2 content in the range of 10.0 to 25.0 wt%, preferably in the range of 12.0 to 20.0 wt%, more preferably in the range of 14.0 to 16.0 wt%, as determined by FT-IR spectroscopy calibrated by quantitative13C-NMR spectroscopy.

[0068] The heterophasic polypropylene copolymer (PPHeco-2) may have a Charpy Notched Impact Strength (NIS) measured according to ISO 179-1 eA at 23°C of at least 20 kJ / m2, preferably at least 25 kJ / m2, like in the range of 20 to 60 kJ / m2, preferably in the range of 25 to 35 kJ / m2, like 28 to 32 kJ / m2.

[0069] The heterophasic polypropylene copolymer (PPHeco-2) may have a flexural modulus measured according to ISO 178 of at least 500 MPa, preferably at least 700 MPa, like in the range of 500 to 1500 MPa, preferably in the range of 700 to 1200 MPa, like 750 to 1000 MPa.

[0070] The heterophasic polypropylene copolymer (PPHeco-2) is known in the art and commercially available for example from Borealis AG.

[0071] It is to be noted that the heterophasic polypropylene copolymer (PPHeco-1) may be preferred over heterophasic polypropylene copolymer (PPHeco-2).

[0072] The synthesis of the virgin heterophasic polypropylene copolymer is now exemplarily described for PPHeco-1.

[0073] PPHeco-1 is preferably obtainable in a multistage polymerization process comparable to the multistage polymerization process in four different pol. Thereby, the temperatures, pressures H2 / C3 ratios, C2 / C3 ratios and residence times in the four subsequent polymerization reactors are accordingly adapted as to produce the heterophasic propylene copolymer PPHeco-1.

[0074] It is preferred that the operating temperature in the first polymerization reactor, preferably the loop reactor, is in the range from 72 to 95 °C, more preferably in the range from 75 to 92 °C, still more preferably in the range from 77 to 90 °C.

[0075] Typically, the pressure in the first polymerization reactor, preferably in the loop reactor, is in the range from 20 to 80 bar, preferably 30 to 70 bar, like 35 to 65 bar.

[0076] It is preferred that in the first polymerization reactor, preferably the loop reactor, a propylene homopolymer is produced. Thus, it is preferred that the first propylene polymer fraction is a propylene homopolymer fraction.

[0077] Preferably hydrogen is added in the first polymerization reactor in order to control the molecular weight, i.e. the melt flow rate MFR2. Preferably, the hydrogen to propylene ratio (H2 / C3 ratio) in the first polypropylene reactor, preferably the loop reactor, is in the range from 35 to 100 mol / kmol, more preferably 50 to 75 mol / kmol.

[0078] It is preferred that the first propylene polymer fraction has a melt flow rate MFR2 (230°C, 2.16 kg, ISO 1133) in the range of 50 to 500 g / 10 min, preferably in the range of 75 to 350 g / 10 min, more preferably in the range of 100 to 250 g / 10 min.

[0079] It is preferred that the operating temperature in the second polymerization reactor, preferably the first gas phase reactor, is in the range from 75 to 95 °C, more preferably in the range from 78 to 92 °C. Typically, the pressure in the second polymerization reactor, preferably in the first gas phase reactor, is in the range from 5 to 50 bar, preferably 15 to 40 bar.

[0080] It is preferred that in the second polymerization reactor, preferably the first gas phase reactor, a propylene homopolymer is produced. Thus, it is preferred that the second propylene polymer fraction is a propylene homopolymer fraction.

[0081] Preferably hydrogen is added in the second polymerization reactor in order to control the molecular weight, i.e. the melt flow rate MFR2. Preferably, the hydrogen to propylene ratio (H2 / C3 ratio) in the second polypropylene reactor, preferably the first gas phase reactor, is in the range from 10 to 50 mol / kmol, more preferably 15 to 35 mol / kmol. It is preferred that the combined first and second propylene polymer fractions have a melt flow rate MFR2 (230°C, 2.16 kg, ISO 1133) in the range of 20 to 150 g / 10 min, preferably in the range of 30 to 100 g / 10 min, more preferably in the range of 40 to 75 g / 10 min.

[0082] It is preferred that the operating temperature in the third polymerization reactor, preferably the second gas phase reactor, is in the range from 75 to 95 °C, more preferably in the range from 78 to 92 °C.

[0083] Typically, the pressure in the third polymerization reactor, preferably in the second gas phase reactor, is in the range from 5 to 50 bar, preferably 15 to 40 bar.

[0084] In the third polymerization reactor, preferably the second gas phase reactor, a propylene ethylene copolymer is produced. Thus, the third propylene polymer fraction is a propylene ethylene copolymer fraction.

[0085] The ethylene to propylene ratio (C2 / C3 ratio) in the third polymerization polymerization reactor, preferably the second gas phase reactor, is in the range from 100 to 500 mol / kmol, more preferably 150 to 300 mol / kmol. Due to the high ethylene to propylene ratio (C2 / C3 ratio) the third propylene copolymer fraction preferably is an elastomeric block copolymer with propylene rich sections and ethylene rich sections.

[0086] Preferably hydrogen is added in the third polymerization reactor in order to control the molecular weight, i.e. the melt flow rate MFR2. Preferably, the hydrogen to ethylene ratio (H2 / C2 ratio) in the third polymerization reactor, preferably the second gas phase reactor, is in the range from 5 to 40 mol / kmol, more preferably 10 to 30 mol / kmol.

[0087] It is preferred that the combined first, second and third propylene polymer fractions have a melt flow rate MFR2 (230°C, 2.16 kg, ISO 1133) in the range of 5 to 100 g / 10 min, preferably in the range of 10 to 75 g / 10 min, more preferably in the range of 15 to 50 g / 10 min.

[0088] It is preferred that the operating temperature in the fourth polymerization reactor, preferably the third gas phase reactor, is in the range from 75 to 95 °C, more preferably in the range from 78 to 92 °C. Typically, the pressure in the fourth polymerization reactor, preferably in the third gas phase reactor, is in the range from 5 to 50 bar, preferably 15 to 40 bar. In the fourth polymerization reactor, preferably the third gas phase reactor, a propylene ethylene copolymer is produced. Thus, the fourth propylene polymer fraction is a propylene ethylene copolymer fraction.

[0089] The ethylene to propylene ratio (C2 / C3 ratio) in the fourth polymerization polymerization reactor, preferably the third gas phase reactor, is in the range from 100 to 500 mol / kmol, more preferably 150 to 300 mol / kmol. Due to the high ethylene to propylene ratio (C2 / C3 ratio) the fourth propylene copolymer fraction preferably is an elastomeric block copolymer with propylene rich sections and ethylene rich sections.

[0090] Preferably hydrogen is added in the fourth polymerization reactor in order to control the molecular weight, i.e. the melt flow rate MFR2. Preferably, the hydrogen to ethylene ratio (H2 / C2 ratio) in the fourth polymerization reactor, preferably the third gas phase reactor, is in the range from 3 to 35 mol / kmol, more preferably 5 to 25 mol / kmol.

[0091] It is preferred that the combined first, second, third and fourth propylene polymer fractions have a melt flow rate MFR2 (230°C, 2.16 kg, ISO 1133) in the range of 3.0 to 30 g / 10min, preferably 4.0 to 25 g / 10min, more preferably 4.5 to 10 g / 10min.

[0092] Further the combined first, second, third and fourth propylene polymer fractions preferably have a total comonomer content, preferably ethylene (C2) content in the range of 5.0 to 20.0 wt.-%, preferably of more preferably of 5.5 to 18.0 wt.-%, based on the total weight of the combined first, second, third and fourth propylene polymer fractions, as determined by FT-IR spectroscopy calibrated by quantitative13C-NMR spectroscopy.

[0093] Preferably the first propylene polymer fraction is present in an amount of from 25 to 45 wt.-%, more preferably from 30 to 40 wt.-%, based on the total weight of the combined first, second, third and fourth propylene polymer fractions. The amount of the polypropylene produced in the pre-polymerization reactor, if present, is generally added to the amount of the first propylene polymer fraction.

[0094] Preferably the second propylene polymer fraction is present in an amount of from 30 to 50 wt.- %, more preferably from 35 to 45 wt.-%, based on the total weight of the combined first, second, third and fourth propylene polymer fractions. Preferably the third propylene polymer fraction is present in an amount of from 5 to 25 wt.-%, more preferably from 10 to 20 wt.-%, based on the total weight of the combined first, second, third and fourth propylene polymer fractions.

[0095] Preferably the fourth propylene polymer fraction is present in an amount of from 3 to 20 wt.-%, more preferably from 5 to 15 wt.-%, based on the total weight of the combined first, second, third and fourth propylene polymer fractions.

[0096] The heterophasic propylene copolymer PPHeco-1 is preferably obtained by a multistage polymerization process, as described above, in the presence of a Ziegler-Natta catalyst system.

[0097] It is appreciated that there are no specific restrictions regarding the catalyst system as long as a Ziegler-Natta catalyst system is used. As regards catalyst systems suitable for preparing the heterophasic propylene copolymer (B), reference is made to e.g. WO 2014 / 023603, EP 591224, WO 2012 / 007430, EP 2415790, EP 2610270, EP 2610271 , EP 2610272, EP 2610273, EP 2960257 and EP 2960256 which are incorporated herein by reference.

[0098] Blend of plastic material, in particular blend of recycled plastic material

[0099] The blend of plastic material used in the present case is preferably obtained from a recycled waste stream. The blend can be either recycled post-consumer waste or post-industrial waste, such as for example from the automobile industry, or alternatively, a combination of both. It is particularly preferred that blend consists of recycled post-consumer waste and / or postindustrial waste.

[0100] In one aspect the blend may be a polypropylene (PP) rich material of recycled plastic material that comprises significantly more polypropylene than polyethylene. Recycled waste streams, which are high in polypropylene can be obtained for example from the automobile industry, particularly as some automobile parts such as bumpers are sources of fairly pure polypropylene material in a recycling stream or by enhanced sorting. PP rich recyclates may also be obtained from yellow bag feedstock when sorted accordingly. The PP rich material may be obtainable by selective processing, degassing and filtration and / or by separation according to type and colors such as NIR or Raman sorting and VIS sorting. It may be obtained from domestic waste streams (i.e. it is a product of domestic recycling) for example the “yellow bag” recycling system organized under the “Green dot” organization, which operates in some parts of Germany.

[0101] Preferably, the polypropylene rich recycled material is obtained from recycled waste by means of plastic recycling processes known in the art. Such PP rich recyclates are commercially available, e.g. from Corepla (Italian Consortium for the collection, recovery, recycling of packaging plastic wastes), Resource Plastics Corp. (Brampton, ON), Kruschitz GmbH (now Steinbeis Polyvert GmbH), Plastics and Recycling (AT), Vogt Plastik GmbH (DE), mtm Plastics GmbH (DE) etc. None exhaustive examples of polypropylene rich recycled materials include: DipolenOPP, PurpolenOPP (Mtm Plastics GmbH), MOPRYLENE PC B-420 White, MOPRYLENE PC B 440 (Morssinkhof Plastics, NL), , SYSTALEN PP-C24000; Systalen PP- C44000; Systalen PP-C14901 , Systalen PP-C17900, Systalen PP-C2400, Systalen 13704 GR 015, Systalen 13404 GR 014, Systalen PP-C14900 GR000 (Der Grune Punkt, DE), Vision (Veolia) PPC BC 2006 HS or PP MONO.

[0102] It is considered that the present invention could be applicable to a broad range of recycled polypropylene materials or materials or compositions having a high content of recycled polypropylene. The polypropylene-rich recycled material may be in the form of granules.

[0103] As mentioned previously, the polyolefin composition in accordance with the present invention comprises as blend a polymer blend, comprising polypropylene and polyethylene; wherein the weight ratio of polypropylene to polyethylene is from 3:7 to 49.5:1 ; and wherein the polymer blend is preferably a recycled material.

[0104] Still a further preferred embodiment of the present invention stipulates that the ratio of polypropylene to polyethylene is from 3:7 to 15:1 , preferably 14:6 to 15:1.

[0105] According to one embodiment, the blend of plastic material, in particular recycled plastic material comprises a relative amount of units derived from propylene of greater than 50 wt%, preferably greater than 53 wt%, more preferably greater than 60 wt%, more preferably greater than 70 wt%, more preferably greater than 75 wt%, more preferably greater than 80 wt%, still more preferably greater than 90 wt% with respect to the total weight of the composition of blend.

[0106] Still a further preferred embodiment of the present invention stipulates that the content of polypropylene in the blend is in the range from 75 - 99 wt% and preferably in the range from 83 - 95 wt% based on the overall weight of blend of recyclate material. The content of polypropylene in blend may be determined by FTIR spectroscopy as described in the experimental section. More preferably the polypropylene component of the blend comprises more than 90 wt% isotactic polypropylene and most preferably consists of isotactic polypropylene.

[0107] Furthermore, the blend may have a relative amount of units derived from ethylene of less than 47 wt%, more preferably less than 40 wt%, more preferably less than 30 wt%, more preferably less than 20 wt%, most preferably less than 10 wt%. The plastic material blend preferably comprises units derived from ethylene in an amount of from 5.0 to 17.5 wt.-%, more preferably from 6.0 to 15.0 wt.-%, still more preferably from 7.5 to 13.0 wt.-%. Usually, the relative amount of units derived from ethylene is more than 5 wt% with respect to the total weight blend. It is to be understood that the ethylene present is preferably ethylene derived from polyethylene and ethylene containing copolymers.

[0108] In another preferred embodiment of the present invention the content of polyethylene in the blend is in the range from 1 - 25 wt%, preferably in the range from 3 - 20 wt%, more preferably in the range from 5 - 20 wt%, even more preferably in the range from 5 - 17 wt%, still more preferably in the range from 7 - 17 wt% based on the overall weight of the blend. The content of polyethylene in blend may be determined by Crystex as described in the experimental section. More, preferably polyethylene component consists of polyethylene and ethylene containing copolymers.

[0109] The blend of plastic material, in particular recycled plastic material is suitably characterized by CRYSTEX QC analysis. In the CRYSTEX QC analysis, a crystalline fraction (CF) and a soluble fraction (SF) are obtained which can be quantified and analyzed in regard of the monomer and comonomer content as well as the intrinsic viscosity (iV).

[0110] The blend of plastic material, in particular recycled plastic material shows one or more, preferably all of the following properties in the CRYSTEX QC analysis: a crystalline fraction (CF) content determined according to CRYSTEX QC analysis in the range from 82.5 to 96.0 wt%, preferably in the range from 84.0 to 95.5 wt%, more preferably in the range from 85.0 to 95.0 wt%, and a soluble fraction (SF) content determined according to CRYSTEX QC analysis in the range from 4.0 to 17.5 wt%, preferably in the range from 4.5 to 16.0 wt%, more preferably in the range from 5.0 to 15.0 wt%. Said crystalline fraction (CF) has one or more, preferably all of the following properties: an ethylene content (C2(CF)), as determined by FT-IR spectroscopy calibrated by quantitative13C-NMR spectroscopy, in the range from 1.0 to 20.0 wt%, preferably in the range from 3 Oto 18.0 wt%, more preferably in the range from 5.0 to 15.0 wt%; and / or an intrinsic viscosity (iV(CF)), as measured in decalin according to DIN ISO 1628 / 1 at 135°C, preferably in the range from 1.0 to below 2.6 dl / g, more preferably in the range from 1.2 to 2.5 dl / g, still more preferably in the range from 1.3 to 2.4 dl / g.

[0111] Said soluble fraction (SF) has one or more, preferably all of the following properties: an ethylene content (C2(SF)), as determined by FT-IR spectroscopy calibrated by quantitative13C-NMR spectroscopy, preferably in the range from 20.0 to 55.0 wt%, preferably in the range from 22.0 to 50.0 wt%, more preferably in the range from 24.0 to 48.0 wt%; and / or an intrinsic viscosity (iV(SF)), as measured in decalin according DIN ISO 1628 / 1 at 135°C, in the range from 0.9 to 2.5 dl / g, preferably in the range from 1.0 to 2.3 dl / g, more preferably in the range from 1.1 to 2.2 dl / g.

[0112] The polyethylene fraction of the recycled material can comprise recycled high-density polyethylene (rHDPE), recycled medium-density polyethylene (rMDPE), recycled low-density polyethylene (rLDPE), linear low density polyethylene (LLDPE) and the mixtures thereof. In a certain embodiment, the recycled material is high density PE with an average density of greater than 0.8 g / cm3, preferably greater than 0.9 g / cm3, most preferably greater than 0.91 g / cm3.

[0113] The polyethylene fraction of the recycled material may also comprise a plastomer. A plastomer is a polymer material that combines rubber-like properties with the processing ability of plastic. Important plastomers are ethylene-alpha olefin copolymers.

[0114] The ethylene based plastomer is preferably a copolymer of ethylene and a C4 - Cs alphaolefin. Suitable C4 - Cs alpha-olefins include 1 -butene, 1 -hexene and 1 -octene, preferably 1- butene or 1 -octene and more preferably 1 -octene. Preferably, copolymers of ethylene and 1- octene are used. Such ethylene based plastomers are commercially available, i.a. from Borealis AG (AT) under the tradename Queo, from DOW Chemical Corp (USA) under the tradename Engage or Affinity, or from Mitsui under the tradename Tafmer. Alternatively, the ethylene based plastomer can be prepared by known processes, in a one stage or two stage polymerization process, comprising solution polymerization, slurry polymerization, gas phase polymerization or combinations therefrom, in the presence of suitable catalysts, like vanadium oxide catalysts or single-site catalysts, e.g. metallocene or constrained geometry catalysts, known to the art skilled persons. It is possible that the ethylene based plastomer is already contained in the post - consumer and / or post-industrial waste being used for the production of recyclate blend. Alternatively, it is possible that the ethylene based plastomer is added to the post-consumer and / or post-industrial waste during the waste plastic recycling process where the recyclate blend is produced.

[0115] Another preferred embodiment of the present invention stipulates that the recyclate blend comprises less than 5 wt%, preferably less than 3 wt% and more preferably from 0.01 to 2 wt% based on the overall weight of the recyclate blend of thermoplastic polymers different from polypropylene and polyethylene, more preferably less than 4.0 wt% PA 6 and less than 5 wt% polystyrene, still more preferably blend comprises 0.5 - 3 wt% polystyrene.

[0116] According to still another preferred embodiment of the present invention the recyclate blend comprises less than 5 wt%, preferably less than 4 wt% and more preferably from 0.01 to 4 wt% based on the overall weight of the recyclate blend of talc.

[0117] In another preferred embodiment of the present invention the recyclate blend comprises less than 4 wt%, preferably less than 3 wt% and more preferably from 0.01 to 2 wt% based on the overall weight of the recyclate blend of chalk.

[0118] According to another preferred embodiment of the present invention the recyclate blend comprises less than 1 wt.-%, preferably less than 0.5 wt% and more preferably from 0.01 to 1 wt% based on the overall weight of the recyclate blend of paper.

[0119] Still another preferred embodiment of the present invention stipulates that the recyclate blend comprises less than 1 wt%, preferably less than 0.5 wt% and more preferably from 0.01 to 1 wt% based on the overall weight of the recyclate blend of wood.

[0120] In another preferred embodiment of the present invention the recyclate blend comprises less than 1 wt%, preferably less than 0.5 wt% and more preferably from 0.01 to 1 wt% based on the overall weight of the recyclate blend of metal.

[0121] According to the present invention, the blend of plastic material, in particular blend of recycled plastic material has a content of limonene as determined using solid phase microextraction (HS-SPME-GC-MS) of 0.1 ppm to 100 ppm, more preferably from 1 ppm to 50 ppm, most preferably from 2 ppm to 35 ppm. Limonene is conventionally found in recycled polyolefin materials and originates from packaging applications in the field of cosmetics, detergents, shampoos and similar products. Therefore, the recyclate blend contains limonene, when the recyclate blend contains material that originates from such types of domestic waste streams.

[0122] The fatty acid content is yet another indication of the recycling origin of the recyclate blend. However, in some cases, the fatty acid content may be below the detection limit due to specific treatments in the recycling process. According to the present invention, the recyclate blend preferably has a content of fatty acids as determined using solid phase microextraction (HS- SPME-GC-MS) of from 1 ppm to 200 ppm, preferably from 1 ppm to 150 ppm, more preferably from 2 ppm to 100 ppm, most preferably from 3 ppm to 80 ppm.

[0123] In a preferred aspect, the recyclate blend (i) contains less than 5 wt%, preferably less than 1.5 wt% polystyrene; and / or (ii) contains less than 3.5 wt%, preferably less than 1 wt% talc; and / or (iii) contains less than 1.0 wt%, preferably less than 0.5 wt% polyamide.

[0124] Due to the recycling origin blend may also contain organic fillers, and / or inorganic fillers, and / or additives in amounts of up to 10 wt%, preferably 3 wt% with respect to the weight of the blend.

[0125] Thus, in an embodiment of the present polyolefin composition the blend of recycled plastic material comprises

[0126] A-1) a content of polypropylene of 50 - 99 wt%,

[0127] A-2) a content of polyethylene of 1 - 40 wt%,

[0128] A-3) 0 - 5.0 wt% of polystyrene and / or copolymers such as ABS,

[0129] A-4) 0 - 3.0 wt% stabilizers,

[0130] A-5) 0 - 4.0 wt% polyamide-6,

[0131] A-6) 0 - 3.0 wt% talc,

[0132] A-7) 0 - 3.0 wt% chalk,

[0133] A-8) 0 - 1.0 wt% paper,

[0134] A-9) 0 - 1.0 wt% wood,

[0135] A-10) 0 to 0.5 wt% metal,

[0136] A-11) 0.1 ppm - 100 ppm of limonene as determined by using solid phase microextraction (HS-SPME-GC-MS), and

[0137] A-12) 0 - 200 ppm total fatty acid content as determined by using solid phase microextraction (HS-SPME-GC-MS) wherein all amounts are given with respect to the total weight of the recyclate blend.

[0138] As stated above the recyclate blend may include one or more further components, selected from:

[0139] A-4) up to 3.0 wt% stabilizers, preferably up to 2.0 wt% stabilizers,

[0140] A-5) up to 4.0 wt% polyamide-6, preferably up to 2.0 wt% polyamide-6,

[0141] A-6) up to 3.0 wt% talc, preferably up to 1.0 wt% talc,

[0142] A-7) up to 3.0 wt% chalk, preferably up tol .O wt% chalk,

[0143] A-8) up to 1 .0 wt% paper, preferably up to 0.5 wt% paper,

[0144] A-9) up to 1 .0 wt% wood, preferably up to 0.5 wt% wood, and

[0145] A-10) up to 0.5 wt% metal, preferably up to 0.1 wt% metal, based on the overall weight of the recyclate blend.

[0146] In one embodiment, the blend of recycled plastic material comprising polypropylene and polyethylene and has a melt flow rate MFR2 (230°C, 2.16 kg, measured according to ISO 1133) of at least 5.0 g / 10 min, preferably of at least 10.0 g / 10 min, more preferably of at least 15.0 g / 10 min, in particular in a range of 5.0 to 70.0 g / 10 min, preferably of 8.0 to 60.0 g / 10 min, more preferably of 10.0 to 50.0 g / 10min.

[0147] According to one embodiment the recycled plastic material may have a melt flow rate MFR2 (ISO 1133, 230°C, 2.16 kg) in the range of 15 to 50 g / 10 min and preferably in the range of 18 to 36 g / 10 min.

[0148] According to another embodiment the recycled plastic material may have a melt flow rate MFR2 (ISO 1133, 230°C, 2.16 kg) in the range of 5 to 20 g / 10 min and preferably in the range of 10 to 15 g / 10 min.

[0149] In a further preferred embodiment of the present invention, the Charpy Notched Impact Strength measured according to ISO 179-1eA at 23°C of the recyclate blend is more than 3.0 kJ / m2, preferably in the range from 4.0 to 8.0 kJ / m2and more preferably in the range from 5.0 to 6.0 kJ / m2.

[0150] A further preferred embodiment of the present invention stipulates that the Tensile Modulus measured according to ISO527-2 of the recyclate blend is in the range of 800 to 1500 MPa and preferably in the range of 1100 to 1400 MPa. In an embodiment, the recyclate blend preferably has one or more, preferably all of the following properties: a melt flow rate MFR2 (230°C, 2.16 kg, ISO1133) of 6.0 to 40 g / 10min, preferably of 8.0 to 40 g / 10min, more preferably of 9.0 to 36 g / 10min; and / or a polydisperstiy index PI of 2.0 to 5.0 Pa'1 , preferably of 2.2 to 4.5 Pa-1, more preferably of 2.5 to 4.0 Pa-1; and / or a complex viscosity at 0.05 rad / s etao.os of from 1000 kPa-s to 5000 kPa-s, preferably of from 1200 kPa-s to 4500 kPa-s, more preferably of from 1400 kPa-s to 4000 kPa-s; and / or a complex viscosity at 300 rad / s eta3oo of 100 kPa-s to 500 kPa-s, preferably of from 150 kPa-s to 400 kPa-s, more preferably of from 175 kPa-s to 300 kPa-s, and / or a density of 905 to 930 kg / m3, preferably from 910 to 925 kg / m3, more preferably from 913 to 922 kg / m3; and / or a limonene content as determined by using solid phase microextraction (HS-SPME-GC- MS): 0.1 ppm to 50 ppm; and / or a tensile modulus of from 1000 MPa to 1500 MPa, preferably from 1100 MPa to 1400 MPa; and / or a Charpy Notched Impact Strength at 23°C (CNIS at 23°C) of from 3.0 to 7.5 kJ / m2, preferably from 4.0 to 7.0 kJ / m2.

[0151] The preferred recyclate blends used in the present polyolefin composition are now described in more detail.

[0152] Recyclate blend A1

[0153] Recyclate Blend 1 that is preferably used is available from mtm Plastics GmbH.

[0154] Blend A1 is a post-consumer recyclate polypropylene based material having a density (determined according to DIN EN ISO 1183) of 915 kg / m3, a melt flow rate (determined according to DIN EN ISO 1133, 230 °C / 2.16 kg) between 20 and 22g / 10 min, %, a tensile modulus (determined according to DIN EN ISO 527, 1 mm / min) of more than 1100 MPa, a yield stress (determined according to DIN EN ISO 527, 50 mm / min) of more than 25 MPa, and a tensile strain at break (determined according to DIN EN ISO 527, 50 mm / min) of more than 13 %. The C2 (SF) content of the soluble fraction of the recyclate blend A1 , as determined by quantitative FT-IR spectroscopy calibrated by13C-NMR spectroscopy, is in a range from 20 - 35 wt%, preferably 25 - 30 wt%, more preferably 26 -30 wt%.

[0155] The C2 (CF) content of the crystalline faction of the recyclate blend A1 , as determined by quantitative FT-IR spectroscopy calibrated by13C-NMR spectroscopy, is in a range from 3 - 15 wt%, preferably 5 - 12 wt%, more preferably 6 -10 wt%.

[0156] Specifically, Blend A1 has a limonene content of below 1 mg / m3, a ratio of PP / PE of 91 / 9, a total C2 content 8-12 wt%, C2 (CF) content 7-9 wt%, C2 (SF) content 27-29 wt%, IV (CF) 1.75 dl / g, IV (SF) 1.38 dl / g, iV (Blend total) 1.73 dl / g, MFR221 - 22 g / 10 min, tensile modulus 1200 - 1300 MPa, Impact strength (charpy test 23°C) 5-6 KJ / m2;

[0157] Blend A2

[0158] Recyclate Blend A2 that is preferably used is also available from mtm Plastics GmbH.

[0159] Blend A2 is a post-consumer recyclate polypropylene based material having a density (determined according to DIN EN ISO 1183) of 915 kg / m3, a melt flow rate (determined according to DIN EN ISO 1133, 230 °C / 2.16 kg) of 11-13 g / 10 min, a tensile modulus (determined according to DIN EN ISO 527, 1 mm / min) of more than 1100 MPa, a yield stress (determined according to DIN EN ISO 527, 50 mm / min) of more than 28 MPa, and a tensile strain at break (determined according to DIN EN ISO 527, 50 mm / min) of more than 47 %.

[0160] The C2 (SF) content of the soluble fraction of the recyclate blend A2, as determined by quantitative FT-IR spectroscopy calibrated by13C-NMR spectroscopy, is in a range from 25 - 45 wt%, preferably 27 - 40 wt%, more preferably 30 - 36 wt%.

[0161] The C2 (CF) content of the crystalline faction of the recyclate blend A2, as determined by quantitative FT-IR spectroscopy calibrated by13C-NMR spectroscopy, is in a range from 4 - 20 wt%, preferably 5 - 16 wt%, more preferably 8 - 14 wt%.

[0162] Specifically, Blend A2 has limonene content of below 1 mg / m3, a ratio of PP / PE of 92 / 8, a total C2 content 8-15 wt%, C2 (CF) content 8-14 wt%, C2 (SF) content 30-36 wt%, IV (CF) 1.57 dl / g, IV (SF) 1.88 dl / g, iV (Blend total) 1.60 dl / g%, MFR211 - 13 g / 10 min, tensile modulus 1200 - 1300 MPa, Impact strength (charpy test 23°C) 5-6 KJ / m2;

[0163] Recyclate blend A1 may be preferred over recyclate blend A2.

[0164] In the following, more specific embodiments of the polyolefin composition are described.

[0165] According to one specific embodiment, a polyolefin composition may be provided, wherein the polyolefin composition comprises a) 55-80 wt%, preferably 55 -70 wt% (based on the overall weight of the polyolefin composition) of the recyclate Blend A1 , b) 20-45 wt%, preferably 30 - 45wt% (based on the overall weight of the polyolefin composition) of the at least one heterophasic polypropylene copolymer (PPHeco) comprising a propylene homopolymer matrix and an elastomer phase dispersed therein;

[0166] Such a composition may have one or more, preferably all of the following properties: an impact strength (ISO179, Charpy 1eA +23°C) in a range between 6.0 and 20.0 kJ / m2, more in particular between 6.5 and 18.0 kJ / m2, even more in particular between 7.0 and 15.0 kJ / m2, and most in particular between 7.5 and 12.0 kJ / m2, a melt flow rate MFR2(230°C, 2.16 kg, measured according to ISO 1133-1) in a range between 8.0 and 30.0 g / 10 min, preferably between 10.0 and 25.0 g / 10min, more preferably between 12.0 and 20.0 g / 10 min, a puncture energy (ISO 6603-2, 23°C) in a range between 10.0 and 25.0 J, more in particular in a range between 12.0 and 22.0 J, even more particular in a range between 15.0 and 20.0 J, a tensile modulus (ISO 527-2, 23°C) in a range between 1100 MPa and 1500 MPa , more in particular in a range between 1100 MPa and 1300 MPa.

[0167] According to a more specific embodiment, a polyolefin composition may be provided, wherein the polyolefin composition comprises a) 55-80 wt%, preferably 55 -70 wt% (based on the overall weight of the polyolefin composition) of the recyclate Blend A1 , b) 20-45 wt%, preferably 30 - 45wt% (based on the overall weight of the polyolefin composition) of the at least one heterophasic polypropylene copolymer (PPHeco-1).

[0168] According to a still more specific embodiment, a polyolefin composition may be provided, wherein the polyolefin composition comprises a) 55-80 wt%, preferably 55 -70 wt% (based on the overall weight of the polyolefin composition) of the recyclate Blend A1 ; b) 20-45 wt%, preferably 30 - 45wt% (based on the overall weight of the polyolefin composition) of the at least one heterophasic polypropylene copolymer (PPHeco-2).

[0169] According to a most preferred embodiment, the polyolefin composition comprises a) 60-70 wt% (based on the overall weight of the polyolefin composition) of the recyclate Blend A1 ; b) 30 - 40 wt% (based on the overall weight of the polyolefin composition) of the at least one heterophasic polypropylene copolymer (PPHeco-1) or (PPHeco-2), having one or more, preferably all of the following properties: an impact strength (ISO179, Charpy 1eA +23°C) in a range between 7.5 and 12.0 kJ / m2, a melt flow rate MFR2 (230°C, 2.16 kg, measured according to ISO 1133-1) in a range between 12.0 and 20.0 g / 10 min, a puncture energy (ISO 6603-2, 23°C) in a range between 15.0 and 20.0 J, a tensile modulus (ISO 527-2, 23°C) in a range between 1100 MPa and 1300 MPa.

[0170] According to another specific embodiment, a polyolefin composition may be provided, wherein the polyolefin composition comprises a) 55-80 wt%, preferably 55 -70 wt% (based on the overall weight of the polyolefin composition) of the recyclate Blend A2; b) 20-45 wt%, preferably 30 - 45wt% (based on the overall weight of the polyolefin composition) of the at least one heterophasic polypropylene copolymer (PPHeco) comprising a propylene homopolymer matrix and an elastomer phase dispersed therein;

[0171] Such a composition may have one or more, preferably all of the following properties: an impact strength (ISO179, Charpy 1eA +23°C) in a range between 6.0 and 20.0 kJ / m2, more in particular between 6.5 and 15.0 kJ / m2, even more in particular between 7.0 and 12.0 kJ / m2, and most in particular between 7.5 and 10.0 kJ / m2, a melt flow rate MFR2 (230°C, 2.16 kg, measured according to ISO 1133-1) in a range between 8.0 and 20.0 g / 10 min, preferably between 9.0 and 15.0 g / 10min, more preferably between 10.0 and 13.0 g / 10 min, a puncture energy (ISO 6603-2, 23°C) in a range between 1.5 and 25.0 J, more in particular in a range between 3.0 and 15.0 J, even more particular in a range between 5.0 and 15.0 J, a tensile modulus (ISO 527-2, 23°C) in a range between 1100 MPa and 1500 MPa , more in particular in a range between 1100 MPa and 1300 MPa.

[0172] According to another specific embodiment, a polyolefin composition may be provided, wherein the polyolefin composition comprises a) 55-80 wt%, preferably 55 -70 wt% (based on the overall weight of the polyolefin composition) of the recyclate Blend A2, b) 20-45 wt%, preferably 30 - 45wt% (based on the overall weight of the polyolefin composition) of the at least one heterophasic polypropylene copolymer (PPHeco-1).

[0173] According to still another specific embodiment, a polyolefin composition may be provided, wherein the polyolefin composition comprises a) 55-80 wt%, preferably 55 -70 wt% (based on the overall weight of the polyolefin composition) of the recyclate Blend A2, b) 20-45 wt%, preferably 30 - 45wt% (based on the overall weight of the polyolefin composition) of the at least one heterophasic polypropylene copolymer (PPHeco-2).

[0174] According to a most preferred embodiment, the polyolefin composition comprises a) 60-70 wt% (based on the overall weight of the polyolefin composition) of the recyclate Blend A2; b) 30 - 40 wt% (based on the overall weight of the polyolefin composition) of the at least one heterophasic polypropylene copolymer (PPHeco-1) or (PPHeco-2), having one or more, preferably all of the following properties: an impact strength (ISO179, Charpy 1eA +23°C) in a range between 7.5 and 10.0 kJ / m2, a melt flow rate MFR2 (230°C, 2.16 kg, measured according to ISO 1133-1) in a range between 10.0 and 13.0 g / 10 min, a puncture energy (ISO 6603-2, 23°C) in a range between 5.0 and 15.0 J, a tensile modulus (ISO 527-2, 23°C) in a range between 1100 MPa and 1300 MPa.

[0175] Additives

[0176] As mentioned previously, the present polyolefin composition may comprise additives, such as coupling agent and / or dosing agent.

[0177] Generally, the amount of these additives is in the range of 0 to 5.0 wt%, preferably in the range of 0.01 to 3.0 wt%, more preferably from 0.01 to 2.0 wt% based on the weight of the total composition.

[0178] In a more preferred embodiment, no coupling agent is added to the polyolefin composition. In one embodiment the polyolefin composition may comprise at least one dosing agent for accepting fillers / pigments during extrusion. The at least one dosing agent may be a polypropylene homopolymer with melt flow rates MFR2 between 1.0 and 5.0 g / 10 min, preferably between 2.0 and 3.0 g / 10 min and a density between 800 and 100 kg / m3, preferably between 900 and 950 kg / m3. Such a polymer is commercially available from Borealis AG. The amount of dosing agent in the polyolefin composition may be 1-2 wt%, such as 1.2-1.4 wt%.

[0179] In a further embodiment the polyolefin composition may comprise further additives. Examples of further additives for use in the composition are pigments or dyes (for example carbon black), stabilizers (anti-oxidant agents), anti-acids and / or anti-UVs, antistatic agents, nucleating agents and utilization agents (such as processing aid agents). Preferred additives are carbon black, at least one antioxidant and / or at least one UV stabilizer. These additives are well known in the polymer industry and their use will be familiar to the skilled practitioner. Any additives, which are present, may be added as an isolated raw material or in a mixture with a carrier polymer, i.e. in a so-called master batch.

[0180] It is appreciated that the present invention also refers to a process for producing the polyolefin compositions as defined herein. The process comprises the steps of

[0181] - providing a mixture of a) 55-98 wt% (based on the overall weight of the polyolefin composition) of a blend of plastic material comprising polypropylene and polyethylene in a ratio between 3:7 and 49.5:1 , , b) 2-45 wt% (based on the overall weight of the polyolefin composition) of at least one heterophasic polypropylene copolymer (PPHeco) with a melt flow rate MFR2 (230°C, 2.16 kg, measured according to ISO 1133) in the range of 1.0 to 25.0 g / 10 min; and c) optionally further additives, wherein the sum of all ingredients always adds up to 100 wt%,

[0182] - melting the mixture in an extruder, and

[0183] - optionally pelletizing the obtained polyolefin composition.

[0184] The present invention is also directed to an article comprising the polyolefin composition according to the invention.

[0185] The polyolefin composition according to the invention can be used for a wide range of applications, for example for manufacturing of appliances, in particular household appliances, structural products, pumps, fans, appliances, automotive parts, pipes and fittings, packaging, caps and closures. Experimental Section

[0186] The following Examples are included to demonstrate certain aspects and embodiments of the invention as described in the claims. It should be appreciated by those of skill in the art, however, that the following description is illustrative only and should not be taken in any way as a restriction of the invention.

[0187] Test Methods

[0188] The following definitions of terms and determination methods apply for the above general description of the invention as well as to the below examples unless otherwise defined.

[0189] Determination of Crystalline and soluble fractions and their respective properties (IV and Ethylene content) via Crystex

[0190] The crystalline (CF) and soluble fractions (SF) of the polypropylene (PP) compositions as well as the comonomer content and intrinsic viscosities of the respective fractions were analyzed by use of the Crystex (crystallisation extraction) method. Potential instruments that can be used are Crystex QC or Crystex 42 (Polymer Char; Valencia, Spain). Details of the technique and the method can be found in literature (Ljiljana Jeremie, Andreas Albrecht, Martina Sandholzer & Markus Gahleitner (2020): Rapid characterization of high-impact ethylenepropylene copolymer composition by crystallization extraction separation: comparability to standard separation methods, International Journal of Polymer Analysis and Characterization, 25:8, 581-596)

[0191] The crystalline and amorphous fractions are separated through temperature cycles of dissolution at 160°C, crystallization at 40°C and re-dissolution in 1 ,2,4-trichlorobenzene at 160°C. Quantification of SF and CF and determination of ethylene content (C2) are achieved by means of an integrated infrared detector (IR4) and for the determination of the intrinsic viscosity (IV) an online 2-capillary viscometer is used.

[0192] IR4 detector is a multiple wavelength detector measuring IR absorbance at two different bands (CH3 stretching vibration (centred at app. 2960 cm-1) and the CH stretching vibration (2700-3000 cm-1) that are serving for the determination of the concentration and the Ethylene content in Ethylene-Propylene copolymers. IR4 detector is calibrated with series of 8 EP copolymers with known Ethylene content in the range of 2 wt.-% to 69 wt.-% (determined by 13C-NMR) and each at various concentrations, in the range of 2 and 13mg / ml. To encounter for both features, concentration and ethylene content at the same time for various polymer concentration expected during Crystex analyses the following calibration equations were applied:

[0193] Cone = a + b*Abs(CH) + c*(Abs(CH))2+ d*Abs(CH3) + e*(Abs(CH3)2+ f*Abs(CH)*Abs(CH3) (Equation 1)

[0194] CH3 / 1000C = a + b*Abs(CH) + c* Abs(CH3) + d * (Abs(CH3) / Abs(CH)) + e * (Abs(CH3) / Abs(CH))2(Equation 2)

[0195] The constants a to f for equation 1 and a to e for equation 2 were determined by using least square regression analysis.

[0196] The CH3 / IOOOC is converted to the ethylene content in wt.-% using following relationship:

[0197] Wt.-% (Ethylene in EP Copolymers) = 100 - CH3 / IOOOTC * 0.3 (Equation 3)

[0198] Amount of Soluble fraction (SF) and Crystalline Fraction (CF) are correlated through the XS calibration to the “Xylene Cold Soluble” (XCS) quantity and respectively Xylene Cold Insoluble (XCI) fractions, determined according to standard gravimetric method as per ISO16152. XS calibration is achieved by testing various EP copolymers with XS content in the range 2-31 Wt%. A linear calibration curve is used.

[0199] Intrinsic viscosity (IV) of the parent EP copolymer and its soluble and crystalline fractions are determined with a use of an online 2-capillary viscometer and are correlated to corresponding I ’s determined by standard method in decalin according to ISO 1628-3. Calibration is achieved with various EP copolymers and PP polymers with IV = 2-4 dL / g. The determined calibration curve is linear.

[0200] The samples to be analyzed are weighed out in concentrations of 10 mg / ml to 20mg / ml.

[0201] After automated filling of the vial with 1 ,2,4-TCB containing 250 mg / l 2,6-tert-butyl-4- methylphenol (BHT) as antioxidant, the sample is dissolved at 170°C until complete dissolution is achieved with either constant stirring or gentle shaking. To avoid sample degradation, polymer solution is blanketed with the N2 atmosphere during dissolution.

[0202] For PP composition containing inorganic fillers or pigments or any other non-TCB soluble polymeric substances removal of these is required. This can be done by hot filtration prior injection.

[0203] A defined volume of the polymer solution is injected into the column filled with inert support where the crystallization of the sample and separation of the soluble fraction from the crystalline fraction is taking place. This process is repeated two times. During the first injection the whole sample is measured at high temperature, determining the I V[dl / g] and the C2[wt%] of the PP composition. During the second injection the soluble fraction (at low temperature) and the crystalline fraction (at high temperature) with the crystallization cycle are measured (Wt% SF, Wt% C2, IV).

[0204] Determination of the content of isotactic polypropylene (iPP), polystyrene (PS), ethylene and Polyamide-6 in blend A)

[0205] Calibration standards were prepared by blending iPP and HDPE to create a calibration curve. The thickness of the films of the calibration standards were 300 pm. For the quantification of the iPP, PS and PA 6 content in the samples quantitative IR spectra were recorded in the solid- state using a Bruker Vertex 70 FTIR spectrometer. Spectra were recorded on 25x25 mm square films of 50-100 pm thickness prepared by compression moulding at 190°C and 4 to 6 mPa. Standard transmission FTIR spectroscopy was employed using a spectral range of 4000 to 400 cm-1, an aperture of 6 mm, a spectral resolution of 2 cm-1, 16 background scans, 16 spectrum scans, an interferogram zero filling factor of 32 and Norton Beer strong apodisation.

[0206] The absorption of the band at 1167 cm-1in iPP was measured and the iPP content was quantified according to a calibration curve (absorption / thickness in cm versus iPP content in wt.-%).

[0207] The absorption of the band at 1601 cm-1(PS) and 3300 cm-1(PA6) were measured and the PS- and PA6 content quantified according to the calibration curve (absorption / thickness in cm versus PS and PA content in wt.-%). The content of ethylene was obtained by subtracting the content of iPP, PS and PA6 from 100. The analysis was performed as double determination.

[0208] Intrinsic viscosity

[0209] The intrinsic viscosity (iV) is measured according to DIN ISO 1628 / 1 , October 1999, in Decalin at 135 °C.

[0210] Melt Flow Rate

[0211] The melt flow rate (MFR) is determined according to ISO 1133 and is indicated in g / 10 min. The MFR is an indication of the flowability, and hence the processability, of the polymer. The higher the melt flow rate, the lower the viscosity of the polymer. The MFR2 of polypropylene is determined at a temperature of 230 °C and a load of 2.16 kg. Density:

[0212] The density is measured according to ISO 1183-187. Sample preparation is done by compression moulding in accordance with ISO 1872-2:2007.

[0213] The xylene soluble fraction at room temperature (XCS, wt.-%): The amount of the polymer soluble in xylene is determined at 25 °C according to ISO 16152; 5thedition; 2005-07-01.

[0214] DSC analysis, melting temperature (Tm) and heat of fusion (Hf), crystallization temperature (Tc) and heat of crystallization (Hc): measured with a TA Instrument Q200 differential scanning calorimetry (DSC) on 5 to 7 mg samples. DSC is run according to ISO 11357 I part 3 / method C2 in a heat I cool I heat cycle with a scan rate of 10 °C / min in the temperature range of -30 to +225 °C. Crystallization temperature (Tc) and crystallization enthalpy (Hc) are determined from the cooling step, while melting temperature (Tm) and melting enthalpy (Hm) are determined from the second heating step.

[0215] The Flexural Modulus is determined according to ISO 178 method A (3-point bending test) on 80 mm * 10 mm x 4 mm specimens. Following the standard, a test speed of 2 mm / min and a span length of 16 times the thickness was used. The testing temperature was 23±2 ° C. Injection moulding was carried out according to ISO 19069-2 using a melt temperature of 230 °C for all materials irrespective of material melt flow rate.

[0216] Notched impact strength (NIS)

[0217] The Charpy notched impact strength (NIS) is measured according to ISO 179 1eA at +23 °C or -20 °C, using injection moulded bar test specimens of 80x 10x4 mm3prepared in accordance with ISO 19069-2 using a melt temperature of 230 °C for all materials irrespective of material melt flow rate.

[0218] Inorganic residues

[0219] Inorganic residues are quantified according to DIN ISO 1172:1996 using a Perkin Elmer TGA 8000. Approximately 10-20 mg of material was placed in a platinum pan. The temperature was equilibrated at 50 °C for 10 minutes, and afterwards raised to 950 °C under nitrogen at a heating rate of 20 °C / min. The ash content was evaluated as the weight % at 850 °C.

[0220] Limonene detection The determination of limonene is based on a static headspace (HS) approach. This analysis uses a combination of a HS sampler with a gas chromatograph (GC) and a mass spectrometer (MS) for screening purposes.

[0221] Samples were delivered to the lab in sealed aluminum-coated polyethylene (PE) bags. Prior to the analysis, samples were cryo-milled, a portion of 2.000 ± 0.100 g was weighed in a 20 ml HS vial and tightly closed. For every sample, a double determination was performed.

[0222] HS / GC / MS parameters

[0223] HS parameters (Agilent G1888 Headspace Sampler)

[0224] Vial equilibration time: 120 min (sample), 5 min (standard)

[0225] Oven temperature: 100 °C (sample), 200 °C (standard)

[0226] Loop temperature: 110 °C (sample), 205 °C (standard)

[0227] Transfer line temperature: 120 °C (sample), 210 °C (standard)

[0228] Low shaking

[0229] • GC parameters (Agilent 7890A GC System)

[0230] Column: ZB-WAX 7HG-G007-22 (30 m x 250 pm x 1 pm)

[0231] Carrier gas: Helium 5.0

[0232] Flow: 2 ml / min

[0233] Split: 5:1

[0234] GC oven program: 35 °C for 0.1 min

[0235] 10 °C / min until 250 °C

[0236] 250 °C for 1 min

[0237] • MS parameters (Agilent 5975C inert XL MSD)

[0238] Acquisition mode: Scan

[0239] Scan parameters:

[0240] Low mass: 20

[0241] High mass: 200

[0242] Threshold: 10

[0243] • Software / Data evaluation

[0244] MSD ChemStation E.02.02.1431

[0245] MassHunter GC / MS Acquisition B.07.05.2479

[0246] AMDIS GC / MS Analysis Version 2.71 NIST / EPA / NIH Mass Spectral Library (2011 version) NIST Mass Spectral Search Program Version 2.0 g

[0247] • AMDIS deconvolution parameters

[0248] Minimum match factor: 80

[0249] Threshold: Low Scan direction: High to Low

[0250] Data file format: Agilent files

[0251] Instrument type: Quadrupole

[0252] Component width: 20

[0253] Adjacent peak subtraction: Two

[0254] Resolution: High

[0255] Sensitivity: Very high

[0256] Shape requirements: Medium

[0257] Solvent tailing: 91 m / z

[0258] Column bleed: 207 m / z

[0259] Min. model peaks: 2

[0260] Min. S / N: 10

[0261] Min. certain peaks: 0.5

[0262] • MSD ChemStation integration parameters

[0263] Integrator: ChemStation

[0264] Initial area reject: 0

[0265] Initial peak width: 0.005

[0266] Shoulder detection: off

[0267] Initial threshold: 10.5

[0268] In this study, the statement “below the limit of detection (< LOD)” describes a condition where either the match factor is below 80 (AM DIS) or the signal to noise ratio (Pk-pk S / N = Corrected signal / Pk-pk noise, MSD ChemStation signal to noise report) of the peak in the sample run is below 3. The results refer solely to the measured samples, time of measurement and the applied parameters.

[0269] Standard solutions

[0270] For a positive identification and comparison with the (lowest) odour detection thresholds (ODT), a limonene standard was used.

[0271] For the HS / GC / MS analysis, 5 pl of the respective standard was injected in a 20 ml HS vial, tightly closed and measured.

[0272] Assuming full vaporisation of the standard substance, the concentration limonene in the HS cGwas estimated as listed in the following

[0273] Tablet Table 1 : Calibration standard and ODT

[0274] Data evaluation

[0275] The concentration of an analyte in the HS cGis calculated by considering the substance amount mGand the available HS volume VG(Equation 1).

[0276] Equation 1

[0277] To estimate the concentration of an analyte in the HS above a polymer sample, the response factor, Rf of a one-point calibration is required (Equation 2). By integrating the extracted ion chromatogram (EIC), the peak area is obtained for the analyte. The corresponding target ion is listed in

[0278] Table 1 . Standard

[0279] RF =CG_

[0280] ■* Peak

[0281] Equation 2

[0282] The concentration of an analyte in the HS above a polymer sample,c^ampleis calculated by multiplying the response factor with the EIC peak area of the sample (Equation 3). PeakareaSamPle

[0283] Equation 3 Additionally, the odour relevance of an analyte in the HS above a polymer sample is estimated by the odour activity value (OAV). Therefore, the concentration of an analyte in the HS above a polymer samplec^ampleis compared with the (lowest) odour detection threshold (ODT) found in literature (Equation 4) [Van Gemert L. J., Odour Thresholds: Compilations of odour threshold values in air, water and other media, Utrecht, Oliemans Punter & Partners BV, 2011], A value above 1 indicates the relevance of an analyte to the odour at the given HS temperature.

[0284] Sample r , cG[mg / m3]

[0285] OAV =

[0286] ODT [mg / m3] Equation 4

[0287] Considerations and limitations

[0288] It must be considered that the ODT for some substances is below the detection limit (LOD) of the method. Therefore, components below the LOD might be missed although still relevant to the overall odour.

[0289] The OAV is based on the assumption that the HS parameters are somewhat relatable to the measurement conditions of an ODT determination. Of course, this is not fully applicable because temperature settings of 100 °C are not necessarily chosen for such experiments and have therefore limited practical value. Nevertheless, this approach can at least indicate the odour relevance of the defined marker substances.

[0290] The tensile properties acc ISO 527-2 (uniaxial tensile test)

[0291] The tensile properties (tensile modulus, tensile strength, tensile stain at strength, tensile stress at break, tensile strain at break) were determined acc. ISO 527-2 method B on 1A ISO 527-2 or 1 B ISO 527-2 dogbones. Following the standard, a testspeed of 1 mm / min was used for tensile modulus and 50mm / min for all other properties. The testing temperature was 23±2° C. Injection or compression moulding was carried out according to ISO 19069-2 (for PP).

[0292] Instrumented Puncture of rigid plastics (ISO 6603- Part 2)

[0293] Maximum force, deflection at maximum force, energy to maximum force, puncture deflection and puncture energy were determined in the instrumented puncture impact behaviour test according to ISO 6603-2. The specimens were injection moulded plaques according to (ISO 19069-2 for PP) and cut to dimensions of 60 mm x 60 mm x 2 mm. The testing conditions used were: impact velocity of 4.4 m / s, with 20 mm diameter lubricated striker, at 23±2°C. The specimens were clamped with a support ring of 40 mm diameter.

[0294] Different blends of recycled material were used. The blends are characterized by the following properties:

[0295] Blend A1

[0296] Blend A1 of recycled plastic material was used ( having a density (determined according to DIN EN ISO 1183) of 915 kg / m3, a melt flow rate (determined according to DIN EN ISO 1133, 230 °C / 2.16 kg) of 21-22 g / 10 min, a tensile modulus (determined according to DIN EN ISO 527, 1 mm / min) of 1200 - 1300 MPa, an impact strength (charpy test 23°C) 5-6 KJ / m2, a yield stress (determined according to DIN EN ISO 527, 50 mm / min) of more than 25 MPa, and a tensile strain at break (determined according to DIN EN ISO 527, 50 mm / min) of more than 13 %.

[0297] Blend A1 has a limonene content of below 1 mg / m3, a ratio of PP / PE of 91 / 9, a total 02 content 8-12 wt%, 02 (OF) content 7-9 wt%, 02 (SF) content 27-29 wt%, IV (OF) 1.75 dl / g, IV (SF) 1.38 dl / g, iV (Blend total) 1.73 dl / g.

[0298] Blend A2

[0299] Blend A2 is a post-consumer recyclate polypropylene based material having a density (determined according to DIN EN ISO 1183) of 915 kg / m3, a melt flow rate (determined according to DIN EN ISO 1133, 230 °C / 2.16 kg) of 11-13 g / 10 min, a tensile modulus (determined according to DIN EN ISO 527, 1 mm / min) of 1200 - 1300 MPa, an impact strength (charpy test 23°C) 5-6 KJ / m2, a yield stress (determined according to DIN EN ISO 527, 50 mm / min) of more than 28 MPa, and a tensile strain (determined according to DIN EN ISO 527, 50 mm / min) of more than 47 %.

[0300] Blend A2 has limonene content of below 1 mg / m3, a ratio of PP / PE of 92 / 8, a total 02 content 8-15 wt%, 02 (OF) content 8-14 wt%, 02 (SF) content 30-36 wt%, IV (OF) 1.57 dl / g, IV (SF) 1.88 dl / g, iV (Blend total) 1.60 dl / g.

[0301] The following Table 2 summarises the properties of Blend A1 and Blend A2:

[0302] Table 2

[0303] Manufacturing of PPHeco-1

[0304] Catalyst system:

[0305] For the polymerization process of PPHeco-1 a traditional trans-esterified high yield MgCh- supported Ziegler-Natta polypropylene catalyst component comprising diethyl phthalate as internal donor (ZN2) was used. The catalyst component and its preparation concept are described in general for example in patent publications EP491566, EP591224 and EP586390. Accordingly, the catalyst component was prepared as follows: first, 0.1 mol of MgChx 3 EtOH was suspended under inert conditions in 250 ml of decane in a reactor at atmospheric pressure. The solution was cooled to -15°C and the 300 ml of cold TiCk was added while maintaining the temperature at said temperature. Then, the temperature of the slurry was increased slowly to 20 °C. At this temperature, 0.02 mol of dioctylphthalate (DOP) was added to the slurry. After the addition of the phthalate, the temperature was raised to 135 °C during 90 minutes and the slurry was allowed to stand for 60 minutes. Then, another 300 ml of TiCk was added and the temperature was kept at 135 °C for 120 minutes. After this, the catalyst was filtered from the liquid and washed six times with 300 ml heptane at 80 °C. Then, the solid catalyst component was filtered and dried.

[0306] Polymerization

[0307] PPHeco-1 was made in prepolymerization I loop reactor I gas phase reactor 1 I gas phase reactor 2 I gas phase reactor 3 configuration followed by a pelletization step. The catalyst systems defined above was used in combination with triethyl-aluminium (TEAL) as co-catalyst and dicyclopentadienyl-dimethoxy silane (donor D) as external donor. The polymerization conditions are summarized in Table 3.

[0308] Table 3

[0309] The polymer powder of PPHeco-1 were compounded in a co-rotating twin-screw extruder Coperion ZSK 47 at 220°C with 0.15 wt.-% antioxidant (Irganox B215FF from BASF AG, Germany; this is a 1 :2-mixture of Pentaerythrityl-tetrakis(3-(3’,5’-di-tert. butyl-4- hydroxyphenyl)-propionate, CAS-no. 6683-19-8, and Tris (2,4-di-t-butylphenyl) phosphite, CAS-no. 31570-04-4); 0.05 wt.-% of of Ca-stearate (CAS-no.1592-23-0, commercially available from Faci, Italy). The CRYSTEX QC analysis and other properties of PPHeco-1 gave the results listed in Table 4.

[0310] Table 4

[0311] PPHeco-2

[0312] PPHeco-2 was obtained in a process analog to the one described for PPHeco-1. CRYSTEX QC analysis and other properties of PPHeco-2 are as follows:

[0313] Pellet: XCS 29 wt%; C2(XCS) 36 wt%; iV(XCS) 2.1 dl / g; MFR213 g / 10 min; Tm 163°C, Tc 112°C CRYSTEX Analysis: SF 31.3 wt%; C2 (total) 15.2 wt%; C2(SF) 39.1 wt%, C2(CF) 5.5 wt%; iV

[0314] (total) 1.8 dl / g; iV (SF) 2.2 dl / g; iV (CF) 1.6 dl / g; iV (SF) / iV (CF) 1.4

[0315] Mechanical properties: flex. Modulus 800 MPa, Charpy NIS (23°C) 19.9 kJ / m2, Charpy NIS (- 20°C) 5.9 kJ / m2

[0316] Antioxidants (for example Irganox B 215 (FF), commercially available from BASF SE) were added in amount up to not more than 2.0 wt% based on the weight of the total composition. Such additives are commonly known. It is to b understood that in case additives are added the amounts of PPHeco and recyclate blend are adapted accordingly, without changing the overall ratio of PPHeco and recyclate blend.

[0317] In Tables 5-8 several examples (comparative-CE; inventive-IE) are summarized.

[0318] Tables 5-6 refer to polyolefin compositions comprising:

[0319] - Comparative Examples (CE1 , CE2): blend of recycled material (Blend A1), no addition of PPHeco;

[0320] - Comparative Example (CE3, CE4): blend of recycled material (Blend A2), no addition of PPHeco;

[0321] - Inventive Examples (IE1 , IE2, IE3): blend of recycled material (Blend A1), addition of PPHeco-2 in varying amounts;

[0322] - Inventive Examples (IE4, IE5, IE6): blend of recycled material (Blend A1), addition of PPHeco-1 in varying amounts;

[0323] - Inventive Examples (IE7, IE8, IE9, IE10): blend of recycled material (Blend A2), addition of PPHeco-2 in varying amounts;

[0324] - Inventive Examples (IE11 , IE12, IE13, IE14): blend of recycled material (Blend A2), addition of PPHeco-1 in varying amounts

[0325] -Comparative Example CE5: blend of recycled material (Blend A2), addition of PPHeco-3 (MFR2of 70 g / 10 min, Tc= 112.3°C);

[0326] - Comparative Example CE6: blend of recycled material (Blend A2), addition of PPHeco-4 (MFR2of 45 g / 10 min);

[0327] As can be seen in Tables 5 and 6 strain at break, impact strength (Charpy), puncture energy measured on any of IE1-IE14 is higher than for CE1-CE6. As can be seen, addition of PPHeco 1-2 can boost the puncture energy of the neat Recyclate. This comes with very limited loss of stiffness (if at all). This means, losing a few percent in stiffness allows to increase toughness up to ten times in case of Blend A2. This means, using any of PPHeco 1-2 PPHeCo can give already application acceptable stiffness values with tough material behaviour at room temperature. Puncture energies up to 20 J can be reached at 1200 MPA.

[0328] Notched Charpy also benefits from the addition of any of PPHeco 1-2 to the recyclate and reaches values above 10 kJ / m2which is reasonable for many targeted applications.

[0329] The effect of PPHeCo on the compound MFR was also investigated. In Table 5, the MFR is plotted as a function of PPHeCO content. The decrease of the MFR is still acceptable for many applications, which makes the investigated compounds an attractive drop-in solution for many applications currently realized with virgin materials.

[0330] Furthermore, in respect to CE5 and CE6 even though a higher amount of heterophasic copolymers PPHeco-3 and PPHeco-4 (each having a higher MFR2 than any of PPHeco 1-2) the toughness of the final compounds indicated by the impact strength (Charpy) does not change or is even lower. This effect of adding rather small amounts of one of the PPHecos 1- 2 to a recyclate Blend was surprising and not predictable.

[0331] Tables 7-8 refer to Comparative Examples (CE7-CE13) based on a heterophasic polypropylene copolymer with a random polypropylene copolymer (RaHECO), as described in US 2022 / 0025150 A1. Said RaHeco is a very soft random heterophasic copolymer with a melt flow rate of 7 g / 10min (230°C / 2.16kg), a flexural modulus of 600 MPa, Charpy impact strength of 10 kJ / m2 and a melting temperature of 142°C,

[0332] When blending said RaHeCo with recyclate Blends, the CE7-CE13 show a lower puncture energy in comparison to the inventive examples. This is in particular true for examples with a higher amount of virgin polymers (HECO or RaHeCo). Furthermore, the type of recyclate used has also an influence on the puncture energy.

[0333] For example, IE3 and IE6 have a tensile modulus (stiffness) I puncture energy ratio of 58 and 60, respectively, whereas CE13 has a tensile modulus (stiffness) I puncture energy ratio of 132.

[0334] IE 9 and IE14 have a tensile modulus (stiffness) I puncture energy ratio of 87 and 168, respectively, whereas CE10 has a tensile modulus (stiffness) / puncture energy ratio of 320. In summary, the final blends with the HECO according to the invention have both a higher stiffness and a higher puncture energy which leads to the better stiffness I puncture energy balance.

[0335]

[0336] able 5: Polyolefin composition and properties thereof

[0337] able 6: Polyolefin composition and properties thereof able 7

[0338] able 8

Claims

Claims1. Polyolefin composition comprising a) 55-98 wt% (based on the overall weight of the polyolefin composition) of a blend of a plastic material comprising polypropylene and polyethylene in a ratio between 3:7 and 49.5: 1 with a content of limonene as determined using solid phase microextraction (HS-SPME-GC-MS) of 0.1 ppm to 100 ppm; b) 2-45 wt% (based on the overall weight of the polyolefin composition) of at least one heterophasic polypropylene copolymer (PPHeco) comprising a propylene homopolymer matrix and an elastomer phase dispersed therein with a melt flow rate MFR2 (230°C, 2.16 kg, measured according to ISO 1133) in the range of 1.0 to 25.0 g / 10 min; and c) optionally further additives, wherein the sum of all ingredients always adds up to 100 wt%,2. Polyolefin composition according to claim 1 , characterized in that it comprises a) 58-95 wt%, preferably 60-90 wt%, preferably 60-80 wt% (based on the overall weight of the polyolefin composition) of the blend of plastic material comprising polypropylene and polyethylene with a content of limonene as determined using solid phase microextraction (HS-SPME-GC-MS) of 0.1 ppm to 100 ppm; b) 5-42 wt%, preferably 10-40 wt%, more preferably 20-40 wt% (based on the overall weight of the polyolefin composition) of the at least one heterophasic polypropylene copolymer (PPHeco) comprising a propylene homopolymer matrix and an elastomer phase dispersed therein; and optionally further additives, wherein the sum of all ingredients always adds up to 100 wt%.

3. Polyolefin composition according to one of the preceding claims characterized by an impact strength (ISO179, Charpy 1eA +23°C) of at least 6.0 kJ / m2, preferably at least 6.5 kJ / m2, more preferably at least 7.0 kJ / m2, in particular in a range between 6.0 and 20.0 kJ / m2, more in particular between 6.5 and 18.0 kJ / m2, even more in particular between 7.0 and 15.0 kJ / m2, and most in particular between 7.5 and 12.0 kJ / m2.

4. Polyolefin composition according to one of the preceding claims, characterized by a melt flow rate MFR2 (230°C, 2.16 kg, measured according to ISO 1133-1) of at least 8.0 g / 10min, preferably of at least 10.0 g / 10min, more preferably of at last 12.0 g / 10min, in particular in a range between 8.0 and 30.0 g / 10 min, preferably between 10.0 and 25.0 g / 10min, more preferably between 12.0 and 20.0 g / 10 min.

5. Polyolefin composition according to one of the preceding claims characterized by a puncture energy (ISO 6603-2, 23°C) of at least 1.5 J, preferably of at least 2.0 J, more preferably of at least 3.0 J, even more preferably of at least 5.0 J, particular in a range between 1.5 and 25.0 J, more in particular in a range between 2.0 and 20.0 J, even more particular in a range between 3.0 and 18.0 J.

6. Polyolefin composition according to one of the preceding claims characterized by a tensile strain at break (ISO 527-2, 23°C) of at least 15.0 %, preferably of at least 20.0 %, more preferably of at least 25.0 %, even more preferably of at least 30.0 %, particular in a range between 15.0 and 120.0 %, more in particular in a range between 20.0 and 100.0 %, even more particular in a range between 25.0 and 90.0 %, still more particular in a range between 30.0 and 80.0 %.

7. Polyolefin composition according to one of the preceding claims, characterized in that the at least one heterophasic polypropylene copolymer (PPHeco) comprising a propylene homopolymer matrix and an elastomer phase dispersed therein has a melt flow rate MFR2 (230°C, 2.16 kg, measured according to ISO 1133) in the range of 2.0 to 20.0 g / 10 min, preferably in the range of 3.0 to 15.0 g / 10 min, more preferably in the range of 5.0 to 11 .0 g / 10 min.

8. Polyolefin composition according to one of the preceding claims, characterized in that the at least one heterophasic polypropylene copolymer (PPHeco) comprising a propylene homopolymer matrix and an elastomer phase dispersed therein has a xylene soluble content (XCS) determined according to ISO 16152 based on the overall weight of heterophasic polypropylene copolymer in the range of 15.0 to 40.0 wt%; preferably in the range of 20.0 to 35.0 wt%, more preferably in the range of 20.0 to 32.0 wt%.

9. Polyolefin composition according to one of the preceding claims, characterized in that the at least one heterophasic polypropylene copolymer (PPHeco) comprising a propylene homopolymer matrix and an elastomer phase dispersed therein has a total C2 content in the range of 5.0 to 30.0 wt%, preferably in the range of 6.0 to 25.0 wt%, more preferably in the range of 8.0 to 20.0 wt%., as determined by FT-IR spectroscopy calibrated by quantitative13C-NMR spectroscopy.

10. Polyolefin composition according to one of the preceding claims, characterized in that the at least one heterophasic polypropylene copolymer (PPHeco) comprising a propylene homopolymer matrix and an elastomer phase dispersed therein is selected from a group comprising- at least one heterophasic polypropylene copolymer (PPHeco-1 ) having a melt flow rate MFR2 (230°C, 2.16 kg, measured according to ISO 1133) in the range of 1.0 to 10.0 g / 10 min, preferably of 2.0 to 8.0 g / 10 min, more preferably of 4.0 to 6.0 g / 10 min, a xylene soluble content (XCS) determined according to ISO 16152 in the range of 20.0 to 30.0 wt%, preferably in the range of 20.0 to 27.0 wt%, more preferably in the range of 20.0 to 24.0 wt%, a total C2 content, as determined by FT-IR spectroscopy calibrated by quantitative13C-NMR spectroscopy, in the range of 5.0 to 15.0 wt%, preferably in the range of 6.0 to 10.0 wt%, more preferably in the range of 7.0 to 8.0 wt%,- at least one heterophasic polypropylene copolymer (PPHeco-2 ) having a melt flow rate MFR2 (230°C, 2.16 kg, measured according to ISO 1133) in the range of 5.0 to 20.0 g / 10 min, preferably of 8.0 to 15.0 g / 10 min, more preferably of 10.0 to 12.0 g / 10 min; a xylene soluble content (XCS) determined according to ISO 16152 in the range of 20.0 to 35.0 wt%, preferably in the range of 25.0 to 32.0 wt%, more preferably in the range of 27.0 to 30.0 wt%, a total C2 content , as determined by FT-IR spectroscopy calibrated by quantitative13C-NMR spectroscopy, in the range of 10.0 to 25.0 wt%, preferably in the range of 12.0 to 20.0 wt%, more preferably in the range of 14.0 to 16.0 wt%, or mixtures thereof.11 . Polyolefin composition according to one of the preceding claims characterized in that the blend of plastic material comprising polypropylene and polyethylene is a blend of recycled plastic material comprising polypropylene and polyethylene in a ratio between 3:7 and 49.5:1 , which is recovered from a waste plastic material derived from postconsumer and / or post-industrial waste.

12. Polyolefin composition according to one of the preceding claims, characterized in that the blend of plastic material comprising polypropylene and polyethylene has a melt flow rate MFR2 (230°C, 2.16 kg, measured according to ISO 1133) of at least 5.0 g / 10 min, preferably of at least 10.0 g / 10 min, more preferably of at least 15.0 g / 10 min, inparticular in a range of 5.0 to 70.0 g / 10 min, preferably of 8.0 to 60.0 g / 10 min, more preferably of 10.0 to 50.0 g / 10min.

13. Polyolefin composition according to one of the preceding claims characterized in that the blend of plastic material, in particular recycled plastic material shows the following properties in the CRYSTEX QC analysis: a crystalline fraction (CF) content determined according to CRYSTEX QC analysis in the range from 82.5 to 96.0 wt%, preferably in the range from 84.0 to 95.5 wt%, more preferably in the range from 85.0 to 95.0 wt%, and a soluble fraction (SF) content determined according to CRYSTEX QC analysis in the range from 4.0 to 17.5 wt%, preferably in the range from 4.5 to 16.0 wt%, more preferably in the range from 5.0 to 15.0 wt%.

14. Polyolefin composition according to claim 13 characterized in that said crystalline fraction (CF) has one or more, preferably all of the following properties: an ethylene content (C2(CF)), as determined by FT-IR spectroscopy calibrated by quantitative13C-NMR spectroscopy, in the range from 1.0 to 20.0 wt%, preferably in the range from 3 Oto 18.0 wt%, more preferably in the range from 5.0 to 15.0 wt%; and / or an intrinsic viscosity (iV(CF)), as measured in decalin according to DIN ISO 1628 / 1 at 135°C, preferably in the range from 1.0 to below 2.6 dl / g, more preferably in the range from 1.2 to 2.5 dl / g, still more preferably in the range from 1.3 to 2.4 dl / g, and said soluble fraction (SF) has one or more, preferably all of the following properties: an ethylene content (C2(SF)), as determined by FT-IR spectroscopy calibrated by quantitative13C-NMR spectroscopy, preferably in the range from 20.0 to 55.0 wt%, preferably in the range from 22.0 to 50.0 wt%, more preferably in the range from 24.0 to 48.0 wt%; and / or an intrinsic viscosity (iV(SF)), as measured in decalin according DIN ISO 1628 / 1 at 135°C, in the range from 0.9 to 2.5 dl / g, preferably in the range from 1.0 to 2.3 dl / g, more preferably in the range from 1.1 to 2.2 dl / g.

15. An article comprising the polyolefin composition according to one of the claims 1-14.

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