POLYMER COMPOSITION COMPRISING A RECYCLED COATED POLYOLEFIN FABRIC SUBSTRATE

Abstract

The present invention relates to a polymer composition comprising the following components: A) 5 to 35 wt.-% based on the overall weight of the polymer composition of a recycled polyolefin fabric substrate; wherein said fabric substrate is coated with a polyolefin composition comprising the following components: a1) an ethylene based plastomer with a density determined according to ISO 1183-1 in the range of 0.857 to 0.915 g/cm3 and a MFR2 (190 C., 2.16 kg) determined according to ISO 1133 in the range of 0.5 to 30 g/10 min; and a2) a propylene based plastomer with a density determined according to ISO 1183-1 in the range of 0.850 to 0.910 g/cm3 and a MFR2 (230 C., 2.16 kg) determined according to ISO 1133 in the range of 0.01 to 30 g/10 min; B) 65 to 95 wt.-% based on the overall weight of the polymer composition of a homopolypropylene or a recycled polymer blend comprising b1) polypropylene and b2) polyethylene, wherein the weight ratio of b1) to b2) is from 3:7 to 12:1; with the proviso that components A) and B) add up to 100 wt.-%. Furthermore, the present invention relates to use of component A) for increasing the Charpy Notched Impact Strength of component B) and to an article comprising the polymer composition according to the present invention.

Claims

1. A polymer composition comprising the following components: A) 5 to 35 wt.-% based on the overall weight of the polymer composition of a recycled coated polyolefin fabric substrate; wherein said fabric substrate is coated with a polyolefin coating composition comprising the following components: a1) an ethylene based plastomer with a density determined according to ISO 1183-1 in the range of 0.857 to 0.915 g/cm.sup.3 and a MFR.sub.2 (190 C., 2.16 kg) determined according to ISO 1133 in the range of 0.5 to 30 g/10 min; and a2) a propylene based plastomer with a density determined according to ISO 1183-1 in the range of 0.850 to 0.910 g/cm.sup.3 and a MFR.sub.2 (230 C., 2.16 kg) determined according to ISO 1133 in the range of 0.01 to 30 g/10 min; B) 65 to 95 wt.-% based on the overall weight of the polymer composition of a homopolypropylene or a recycled polymer blend comprising b1) polypropylene and b2) polyethylene, wherein the weight ratio of b1) to b2) is from 3:7 to 12:1.

2. The polymer composition according to claim 1, wherein the content of the coating composition in component A) is in the range of 5 to 90 wt.-%, based on the overall weight of component A).

3. The polymer composition according to claim 1, characterized in that: the ethylene based plastomer a1) is a copolymer of ethylene and at least one C3 to C10 alpha-olefin; the propylene based plastomer a2) is a copolymer of propylene and ethylene or a C4 to C10 alpha-olefin; or a combination thereof.

4. The polymer composition according to claim 1, characterized in that: the ethylene based plastomer a1) has a density determined according to ISO 1183-1 in the range of 0.860 to 0.915 g/cm.sup.3, and/or a MFR.sub.2 (190 C., 2.16 kg) determined according to ISO 1133 in the range of 2.5 to 12 g/10 min; the propylene based plastomer a2) has a density determined according to ISO 1183-1 in the range of 0.855 to 0.900 g/cm.sup.3 and/or a MFR.sub.2 (230 C., 2.16 kg) determined according to ISO 1133 in the range of 3.0 to 22 g/10 mini; or a combination thereof.

5. The polymer composition according to claim 1, characterized in that component A) further comprises a flame retardant a3).

6. The polymer composition according to claim 5, characterized in that: the content of component a1) in the coating composition of component A) is in the range of 40 to 65 wt. %, based on the overall weight of component A); and/or the content of component a2) in the coating composition of component A) is in the range of 20 to 40 wt. %, based on the overall weight of component A); and/or the content of component a3) in the coating composition of component A) is in the range of 5 to 20 wt. %, based on the overall weight of component A); or a combination thereof.

7. The polymer composition according to claim 1, characterized in that: the content of component A) in the polymer composition is in the range of 9 to 31 wt.-% based on the overall weight of the polymer composition; the content of component B) in the polymer composition is in the range of 69 to 91 wt.-%, based on the overall weight of the polymer composition; or a combination thereof.

8. The polymer composition according to claim 1, characterized in that the polymer composition further comprises at least one additive present in an amount of from 0.1 to 10 wt.-% based on the overall weight of the polymer composition.

9. The polymer composition according to claim 1, characterized in that component B) is a homopolypropylene having: a MFR.sub.2 (230 C., 2.16 kg) determined according to ISO 1133 in the range of 10 to 30 g/10 min; a melting point determined according to IO 11357-3 in the range of 158 to 163 C.; or a combination thereof.

10. The polymer composition according to claim 1, characterized in that component B) is a recycled polymer blend comprising b1) polypropylene and b2) polyethylene, wherein the weight ratio of b1) to b2) is from 3:7 to 12:1; and wherein component (B) comprises 80.0 to 99.9 wt. %, based on the overall weight of component B) of polypropylene b1) and polyethylene b2).

11. The polymer composition according to claim 1, characterized in that component B) comprises less than 5 wt. % based on the overall weight of component B) of thermoplastic polymers different from b1) and b2).

12. The polymer composition according to claim 1, characterized in that component B) is recovered from waste plastic material derived from post-consumer and/or post-industrial waste.

13. The polymer composition according to claim 1, characterized in that the MFR.sub.2 (230 C., 2.16 kg) determined according to ISO 1133 of component B) is in the range of 16 to 50 g/10 min.

14. The polymer composition according to claim 1, wherein the fabric substrate comprises polypropylene.

15. The polymer composition according to claim 1, wherein the content of the fabric substrate is in the range of 8 to 50 wt. % based on the overall weight of component A).

16. A process for the preparation of a polymer composition, the process comprising: obtaining a recycled coated polyolefin fabric substrate, wherein said fabric substrate is coated with a polyolefin coating composition comprising the following components: a1) an ethylene based plastomer with a density determined according to ISO 1183-1 in the range of 0.857 to 0.915 g/cm.sup.3 and a MFR.sub.2 (190 C., 2.16 kg) determined according to ISO 1133 in the range of 0.5 to 30 g/10 min; and a2) a propylene based plastomer with a density determined according to ISO 1183-1 in the range of 0.850 to 0.910 g/cm.sup.3 and a MFR.sub.2 (230 C., 2.16 kg) determined according to ISO 1133 in the range of 0.01 to 30 g/10 min; shredding the recycled coated polyolefin fabric substrate to form shreds of recycled coated polyolefin fabric substrate; and combining: A) 5 to 35 wt.-% based on the overall weight of the polymer composition of said shreds of recycled coated polyolefin fabric substrate; and B) 65 to 95 wt.-% based on the overall weight of the polymer composition of a homopolypropylene or a recycled polymer blend comprising b1) polypropylene and b2) polyethylene, wherein the weight ratio of b1) to b2) is from 3:7 to 12:1.

17. A method of use of component A) for increasing the Charpy Notched Impact Strength measured according to ISO 179-1eA at 23 C. of component B), whereby component B) is present in amount of 65 to 90 wt.-% based on the overall weight of components A) and B); wherein component A) is a recycled coated polyolefin fabric substrate; wherein said fabric substrate is coated with a polyolefin coating composition comprising the following components: a1) an ethylene based plastomer with a density with a density determined according to ISO 1183-1 in the range of 0.850 to 0.915 g/cm.sup.3 and a MFR.sub.2 (190 C., 2.16 kg) determined according to ISO 1133 in the range 0.5 to 30 g/10 min; and a2) a propylene based plastomer with a density determined according to ISO 1183-1 in the range of 0.860 to 0.910 g/cm.sup.3 and a MFR.sub.2 (230 C., 2.16 kg) determined according to ISO 1133 in the range of 0.01 to 30 g/10 min; and wherein component B) is a homopolypropylene or a recycled polymer blend comprising b1) polypropylene and b2) polyethylene, wherein the weight ratio of b1) to b2) is from 3:7 to 12:1.

18. The method of use as claimed in claim 17, wherein component A) is present in amount of 5 to 35 wt.-% based on the overall weight of components A) and B).

19. The method of use according to claim 17, characterized in that: component B) is homopolypropylene and the Charpy Notched Impact Strength of component B) measured according to ISO 179-1eA at 23 C. is increased by 25 to 150%; or component B) is a recycled polymer blend comprising b1) polypropylene and b2) polyethylene, wherein the weight ratio of b1) to b2) is from 3:7 to 12:1 and the Charpy Notched Impact Strength of component B) measured according to ISO 179-1eA at 23 C. is increased by 10 to 100%.

20. The method of use according to claim 17, characterized in that component B) is a recycled polymer blend comprising b1) polypropylene and b2) polyethylene, wherein the weight ratio of b1) to b2) is from 3:7 to 12:1 and the Tensile Strain at Break measured according to ISO 527-2 is increased by 20 to 250%.

21. The method of use se according to claim 17, characterized in that component A) further comprises a flame retardant a3).

22. The method of use according to claim 17, characterized in that component A) is used in shredded form, as pellets, as flakes, as powder or as granules.

23. An article comprising the polymer composition as defined in claim 1.

24. The article according to claim 23, wherein the article is selected from the group consisting of consumer goods or houseware.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0152] FIGS. 1a-c, 2a-c and 3a-c show the FTIRs for blue, white and black recycled coated polyolefin fabric substrate.

EXPERIMENTAL PART

[0153] A. Measuring Methods

[0154] 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.

[0155] Melt Flow Rate

[0156] The melt flow rate (MFR) was determined according to ISO 1133Determination of the melt mass-flow rate (MFR) and melt volume-flow rate (MVR) of thermoplasticsPart 1: Standard method 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 MFR.sub.2 of polyethylene-based plastomers is determined at a temperature of 190 C. and a load of 2.16 kg. The MFR.sub.2 of polypropylene-based plastomers is determined at a temperature of 230 C. and a load of 2.16 kg.

[0157] Density

[0158] Density of the materials was measured according to ISO 1183-1. Sample preparation is done by compression moulding in accordance with ISO 1872-2.

[0159] Tensile Modulus, Tensile Strength, Tensile Strain at Break, Tensile Strain at Tensile Strength, Tensile Stress at Break

[0160] The measurements were conducted after 96 h conditioning time (at 23 C. at 50% relative humidity) of the test specimen. The test specimen were prepared according to ISO 294-1.

[0161] Tensile Modulus was measured according to ISO 527-2 (cross head speed=1 mm/min; 23 C.).

[0162] Tensile Strength was measured according to ISO 527-2 (cross head speed=50 mm/min; 23 C.).

[0163] Tensile Strain at Break was measured according to ISO 527-2 (cross head speed=50 mm/min; 23 C.).

[0164] Tensile Strain at Tensile Strength was determined according to ISO 527-2 with an elongation rate of 50 mm/min until the specimen broke.

[0165] Tensile Stress at Break was determined according to ISO 527-2 (cross head speed=50 mm/min).

[0166] Tensile Stress at Yield was determined according to ISO 527-2 (cross head speed=50 mm/min).

[0167] Charpy Notched Impact Strength

[0168] Charpy Notched impact strength was determined (after 96 hours of conditioning at 23 C. and % relative humidity) according to ISO 179 1eA at 23 C. and 20 C. using 80104 mm.sup.3 test bars injection moulded in line with EN ISO 1873-2.

[0169] Determination of the Content of Isotactic Polypropylene (iPP), Polystyrene (PS), Ethylene and Polyamide-6 in Purpolen

[0170] 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 m. 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 2525 mm square films of 50-100 m 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.sup.1, an aperture of 6 mm, a spectral resolution of 2 cm.sup.1, 16 background scans, 16 spectrum scans, an interferogram zero filling factor of 32 and Norton Beer strong apodisation.

[0171] The absorption of the band at 1167 cm.sup.1 in iPP was measured and the iPP content was quantified according to a calibration curve (absorption/thickness in cm versus iPP content in wt.-%).

[0172] The absorption of the band at 1601 cm.sup.1 (PS) and 3300 cm.sup.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.

[0173] B. Materials Used

[0174] Component A): Recycled Coated Polyolefin Fabric Substrate Component

[0175] Recycled coated polyolefin fabric substrates in sheet form were shredded by using a Wittmann mill at ambient temperature into small pieces which are about the same size of a standard polymer pellet. The used polyolefin fabric substrate is a PP-based knitted fabric having on top 2 thin layers (thickness approx. 0.09 mm and 0.4 mm), each comprising the coating composition as defined in Table 1, as well as lacquers in the amounts as specified below. The lacquers are consisting of other non-polyolefin based resins, mainly polyurethane and polyacrylate.

[0176] Recycled coated polyolefin fabric substrates were subjected to analysis via FTIR. FTIR analysis of three recycled coated polyolefin fabric substrates (the same other than in colour) showed that all 3 samples are 3-layer structures comprising: [0177] Urethane and/or silicon based resins in the lacquer layer [0178] EPR, PE plastomer in the coating layer [0179] PP-homopolymer in the fabric substrate

[0180] FIGS. 1a-c, 2a-c and 3a-c show the FTIRs for blue, white and black recycled coated polyolefin fabric substrate.

[0181] Lacquer: 5.0 wt.-% based on the total weight of the coated polyolefin fabric substrate Coating composition: 65 wt.-% based on the total weight of the coated polyolefin fabric substrate

[0182] Polypropylene fabric: 30 wt.-% based on the total weight of the coated polyolefin fabric substrate (thickness: 0.5 mm)

TABLE-US-00001 TABLE 1 Composition of the coating of the recycled polyolefin fabric substrate. Content Tradename/ [wt.-%] Description Supplier 45.8 Ethylene based plastomer: an ethylene octene Queo 7007LA/ metallocene plastomer, density = 0.870 g/cm.sup.3, Borealis AG MFR2 (190 C./2.16 kg) = 6.6 g/10 min (=component a1) 11.0 Ethylene based plastomer: an ethylene octene Queo 020/ metallocene plastomer, density = 0.902 g/cm.sup.3, Borealis AG MFR2 (190 C./2.16 kg) = 3 g/10 min (=component a1) 31.45 Random propylene ethylene metallocene Vistamaxx 6202/ plastomer, density = 0.862 g/cm.sup.3, MFR2 Exxon Mobile (230 C., 2.16 kg) = 20 g/10 min (=component a2) 11.0 Ammonium polyphosphate ADKSTAB (flame retardant = component a3) FP2500S/ ADEKA Polymer Additives Europe 0.75 Stabilizer mixture comprising UV-stabilizers and antioxidants

[0183] Component B)

[0184] Recycled Polymer Blend (Purpolen PP)

[0185] Purpolen PP is a recycled polymer mixture comprising as main components polyethylene and polypropylene obtained from mtm plastics GmbH, Niedergebra (Germany).

TABLE-US-00002 TABLE 2 Composition of the recycled polymer blend. content of content of of component b1) component b2) determined determined by FTIR by FTIR (PP) (PE) Purpolen 87.4 wt.-% 10.5 wt.-% Purpolen adds up with PS and PA 6 (content also determined by FTIR) to 100 wt.-%.

[0186] Virgin Homopolypropylene (HF420FB) [0187] HF420FB: HF420FB is a polypropylene homopolymer, commercially available by Borealis AG (Austria), Melt Flow Rate (230 C./2.16 kg, ISO 1133) of 19.0 g/10 min and melting temperature (determined by DSC according to ISO 11357/03) of 1161 C.

[0188] C. Manufacturing of the Polymer Composition

[0189] The polymer compositions according to the Inventive Examples 1E1 to 1E6 were manufactured by feeding component A) into a co-rotating twin screw side feeder (extruder prism TSE 24MC) which allowed an accurate feeding and dosing of the material into the extruder. Component B) was fed in the form of granules into the same extruder via the main hopper. In the extruder components A) and B) were melt blended (230 C., output rate 6 kg/hour) and subsequently pelletized by an underwater cooling system. The obtained pellets were collected, dried and submitted tested. The materials according to CE1 and CE3 were not compounded. The amounts of the different components in the polymer compositions and the properties of the polymer compositions according to the inventive examples and the comparative examples can be gathered from below Tables 3 and 4.

TABLE-US-00003 TABLE 3 Composition and properties of the polymer compositions comprising a virgin homopolypropylene. Unit IE1 IE2 IE3 CE1 CE2 Component Recycled coated polyolefin wt.-% 10 20 30 100 fabric substrate (A) HF420B (B) wt.-% 90 80 70 100 Properties MFR.sub.2 g/10 19.4 19.0 18.8 19.5 n.d. min Tensile Modulus MPa 1170 1020 948 1270 266 Tensile Stress at Yield MPa 29.3 25.6 23.8 31.6 n.d. Tensile Strength MPa 29.3 25.6 23.8 31.6 9.3 Tensile Strain at Tensile % 11.2 12.0 13.2 10.7 358 Strength Tensile Stress at Break MPa 13.4 n.d. n.d. 17.4 9.1 Tensile Strain at Break % 616 n.d. n.d. 628 360 Charpy Notched Impact kJ/m.sup.2 3.6 4.3 5.2 2.3 n.d. Strength 23 C. n.d. = not determined.

TABLE-US-00004 TABLE 4 Composition and properties of the polymer compositions comprising a recycled polymer blend. Component Unit IE4 IE5 IE6 CE3 Recycled coated polyolefin wt.-% 10 20 30 100 fabric substrate (A) Purpolen PP (B) wt.-% 90 80 70 Properties MFR.sub.2 g/10 min 22.6 22.2 21.3 24.0 Tensile Modulus MPa 1094 962 834 1268 Tensile Stress at Yield MPa 22.5 20.6 18.7 25.0 Tensile Strength MPa 22.5 20.6 18.7 25.0 Tensile Strain at Tensile % 5.8 7.4 10.2 5.0 Strength Tensile Stress at Break MPa 17.1 12.7 12.3 20.3 Tensile Strain at Break % 18.2 26.9 46.1 14.1 Charpy Notched Impact kJ/m.sup.2 6.6 8.3 10.0 5.3 Strength 23 C.

[0190] D Discussion of the Results

[0191] As can be seen from Table 3 the addition of a recycled polyolefin fabric substrate to a virgin polypropylene significantly improves the toughness, expressed by the Charpy Notched Impact Strength at 23 C., of the polymer composition while the stiffness of the material is still at a good level. The experimental data according to Table 4 confirm that said technical effect is also observed in recycled polymer blends. In addition, the presence of a recycled polyolefin fabric substrate in a recycled polymer blend also significantly improves the Tensile Strain at Break of the polymer composition.