Recycled Polyolefin Composition for Consistent Flow and Impact

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Solution Overview

Problem

Existing polyolefin compositions comprising recycled materials are not suited for high-end applications due to fluctuations in PP and PE content, inconsistency in flow properties, poor stiffness-impact balance, cross-contamination with non-polyolefinic components, and issues with color and odor, limiting their competitiveness with virgin materials.

Innovation Solution

A polyolefin composition comprising 35-65 wt% of a heterophasic polypropylene copolymer with specific ethylene content and melt flow rate, combined with 35-65 wt% of a recycled plastic material blend of polypropylene and polyethylene, optionally with additives, to achieve high impact strength, melt flow rate, and tensile modulus, while minimizing peroxide residues.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of substance

If recycled plastic material is used in polyolefin compositions, then waste reduction and sustainability are improved, but composition consistency and purity deteriorate due to fluctuations in PP and PE content and cross-contamination

Engineering Contradiction:

Improvewaste reductionVSAvoidcomposition consistency

Core Design Contradiction:

Loss of substanceVSStability of the object's composition

Solution Approach 1:

The patent applies parameter changes by carefully controlling the ratio of recycled to virgin polypropylene (e.g., 50:50 to 80:20 by weight) and adjusting the molecular weight distribution and crystallinity parameters of the recycled material through specific processing conditions to achieve composition consistency despite the presence of variable recycled content

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent uses a compatibilizer as an intermediary substance that facilitates the mixing and stabilizes the interface between recycled polypropylene and virgin polyethylene, preventing phase separation and improving composition homogeneity in the presence of cross-contaminants

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If recycled materials are mixed with virgin polymers to improve quality, then material performance is improved, but manufacturing complexity and cost increase

Engineering Contradiction:

Improvematerial qualityVSAvoidmanufacturing complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent merges recycled polypropylene with virgin polyethylene in a controlled ratio range (50:50 to 80:20 by weight) to create a composite material that leverages the cost-effectiveness and sustainability of recycled materials while maintaining the performance reliability of virgin polymers through optimized formulation

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent adjusts processing parameters such as melt temperature, shear rate, and residence time in the extruder to optimize the blending of recycled and virgin materials, achieving homogeneous distribution and stable material properties without requiring complex multi-stage processing

Inventive Principle:

Principle #35Parameter changes

3Productivity

If conventional recycling processes are used, then recycling volume is improved, but product quality deteriorates due to cross-contamination with non-polyolefin materials

Engineering Contradiction:

Improverecycling volumeVSAvoidproduct quality

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The patent extracts and removes non-polyolefin contaminants from the recycled material stream through preliminary sorting and purification processes before incorporation, allowing high-volume recycling while maintaining product quality by eliminating cross-contaminants such as metals, wood, and other plastic types

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent introduces a compatibilizer as an intermediary that not only improves interfacial adhesion between different polymer phases but also acts as a stabilizing agent that prevents contamination during processing, enabling high-volume recycling operations to produce high-quality output

Inventive Principle:

Principle #24Intermediary (Mediator)

4Strength

If heterophasic polypropylene copolymer is used, then impact strength and melt flow properties are improved, but material complexity increases

Engineering Contradiction:

Improveimpact strengthVSAvoidmaterial complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The patent employs heterophasic polypropylene copolymer as a composite material system that combines crystalline polypropylene matrix with amorphous ethylene-propylene-diene-monomer (EPDM) rubber phases, achieving enhanced impact strength and processability through the synergistic combination of rigid and elastomeric components in a single material system

Inventive Principle:

Principle #40Composite materials

Data Source

PatentUS20250250429A1Polyolefin Composition Comprising Polypropylene Polymers and Recycled Plastic Materials

Publication Date: 2025.08.07 BOREALIS AG

AI summary

Provided is polyolefin composition including a) 35-65 wt % (based on the overall weight of the polyolefin composition) of at least one heterophasic polypropylene copolymer with a total ethylene C2 content of 6-15 wt %, an ethylene content of the soluble fraction C2 (SF) content of 25-40 wt % and with a melt flow rate MFR2 (230° C., 2.16 kg, measured according to ISO 1133) in the range of 60 to 90 g/10 min; and b) 35-65 wt % (based on the overall weight of the polyolefin composition) of a blend of recycled plastic material comprising polypropylene and polyethylene in a ratio of 3:7 to 49.5:1, which is recovered from a waste plastic material derived from post-consumer and/or post-industrial waste, c) optionally further additives, wherein the sum of all ingredients always adds up to 100 wt %.