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1. WO2020221739 - POLYPROPYLENE-POLYETHYLENE COMPOSITION WITH IMPROVED TOUGHNESS

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[ EN ]

Claims

1. A polymer composition comprising at least the following components

A) 40 to 94 wt.-% based on the overall weight of the polymer composition of a

polymer blend, comprising

a1) 50 to 95 wt.-% of polypropylene;

a2) 5 to 50 wt.-% of polyethylene;

B) 3 to 30 wt.-% based on the overall weight of the polymer composition of a

compatibilizer being a copolymer of propylene and 1 -hexene, comprising b1) 30 to 70 wt.-% of a first random copolymer of propylene and 1 -hexene; and b2) 30 to 70 wt.-% of a second random copolymer of propylene and 1 -hexene having a higher 1 -hexene content than the first random propylene copolymer b1);

C) 3 to 30 wt.-% of a modifier selected from the group consisting of plastomers, heterophasic polypropylene copolymers different from component B) and mixtures thereof;

with the provisos that

• the weight proportions of components a1) and a2) add up to 100 wt.-%;

• the weight proportions of components b1) and b2) add up to 100 wt.-%;

• the weight proportions of components A), B) and C) add up to 100 wt.-%;

• component A) has a MFR2 (230°C, 2.16 kg) determined according to ISO 1133 in the range from 1.0 to 50.0 g/10 min; and

• component B) has a 1 -hexene content in the range from 2.0 to 8.0 wt.-%.

2. The polymer composition according to claim 1 , characterized in that,

component C) is a plastomer comprising ethylene, preferably a copolymer of ethylene and 1-octene, more preferably having a density in the range from 0.860 to 0.930 g/cm3, even more preferably having a MFR2 (190°C, 2.16 kg) determined according to ISO 1133 in the range from 0.1 to 40.0 g/10 min and most preferably is a copolymer of ethylene and 1-octene having a density in the range from 0.865 to 0.920 g/cm3 and a MFR2 (190°C, 2.16 kg) determined according to ISO 1133 in the range from 0.3 to 35 g/10 min; and/or

component C) is a heterophasic polypropylene copolymer comprising

c1) 70.0 to 90.0 wt% of a crystalline polypropylene matrix; and

c2) 10.0 to 30.0 wt% of an amorphous propylene-ethylene copolymer comprising 35.0 to 70.0 wt% of ethylene;

wherein the weight proportions of components d) and c2) add up to 100 wt.-%;

preferably the heterophasic polypropylene copolymer C) has a MFR2 (230°C, 2.16 kg) determined according to ISO 1133 in the range from 1.0 to 10.0 g/10 min.

3. The polymer composition according to claim 1 or 2, characterized in that,

the content of component A) in the polymer composition is in the range from 50 to 91 wt.-%, preferably in the range from 58 to 87 wt.-% and more preferably in the range from 83 to 87 wt.-% when component C) is a plastomer or in the range from 73 to 81 when component C) is a heterophasic polypropylene copolymer based on the overall weight of the polymer composition; and/or

the content of component B) in the polymer composition is in the range from 5 to 25 wt.-%, preferably in the range from 8 to 22 wt.-% and more preferably in the range from 9 to 11 wt.-% based on the overall weight of the polymer composition; and/or

the content of component C) in the polymer composition is in the range from 4 to 25 wt.-%, preferably in the range from 5 to 20 wt.-% and more preferably in the range from 4 to 6 wt.-% for plastomers or from 10 to 16 wt.-% based on the overall weight of the polymer composition for heterophasic polypropylene copolymers; and/or

the content of polypropylene a1) in component A) is in the range from 53 to 92 wt.-%, preferably in the range from 55 to 90 wt.-% and more preferably in the range from 58 to 87 wt.-%; and/or

the content of polyethylene a2) in component A) is in the range from 8 to 47 wt.-%, preferably in the range from 10 to 45 wt.-% and more preferably in the range from 13 to 42 wt.-%.

4. The polymer composition according to one of the preceding claims, characterized in that,

component A) has a MFR2 (230°C, 2.16 kg) determined according to ISO 1133 in the range from 1.5 to 35.0 g/10 min, preferably in the range from 2.0 to 25.0 g/10 min and more preferably in the range from 5.0 to 10.0 g/10 min; and/or

component B) has a MFR2 (230°C, 2.16 kg) determined according to ISO 1133 in the range from 0.4 to 12.0 g/10 min, preferably in the range from 0.6 to 9.0 g/10 min, more preferably in the range from 0.8 to 6.0 g/10 min and most preferably in the range from 1.0 to 4.0 g/10 min; and/or

component B) has a xylene soluble content (XCS) based on the overall weight of component B) of ³ 8, preferably in the range from 8 to 30 wt.-%, more preferably in the range from 10.0 to 28.0 wt.-% and most preferably in the range from 15 to 28 wt- %; and/or

the 1 -hexene content in component B) is in the range from 3.0 to 7.5 wt.-%, preferably in the range from 3.5 to 7.2 wt.-% and more preferably in the range from 4.0 to 6.0 wt.-%; and/or

component B) has a 1 -hexene content of the xylene soluble fraction C6 (XCS) based on the overall weight of component B) in the range from 2.0 to 15.0 wt.-%, preferably from 2.5 to 12.0 wt.-%, more preferably in the range from 3.0 to 10.0 wt.-% and most preferably in the range from 5.0 to 8.0 wt.-%; and/or

the melting point of component B) is >120°C, preferably in the range from 125 to 145°C and more preferably in the range from 130 to 140°C; and/or

the melt enthalpy of component a2) / melt enthalpy of a1) in the polymer composition is in the range from 0.2 to 2.0 and preferably in the range from 0.25 to 1.75.

5. The polymer composition according to any one of the preceding claims, characterized in that, the polymer composition has

a MFR2 (230°C, 2.16 kg) determined according to ISO 1133 in the range from 1.0 to 50.0 g/10 min, preferably from 1.5 to 35.0 g/10 min, more preferably from 2.0 to 25.0 g/10 min and most preferably from 3.5 to 8.0 g/10 min; and/or

a Tensile Modulus measured according to IS0527-2 in the range from 800 to 1500 MPa and preferably in the range from 800 to 1000 MPa; and/or

an Elongation at Break measured according to ISO 527-2 of more than 300 %, preferably in the range from 350 to 1000 % and more preferably in the range from 400 to 900 %; and/or

a Charpy Notched Impact Strength measured according to ISO 179-1eA at 23°C of more than 8,0 kJ/m2, preferably in the range from 8.5 to 30 kJ/m2, more preferably in the range from 9.0 to 25 kJ/m2 and more preferably in the range from 9 to 11 kJ/m2.

6. The polymer composition according to any one of the preceding claims, characterized in that,

component b1) has a MFR2 (230°C, 2.16 kg) determined according to ISO 1133 in the range from 0.3 to 12.0 g/10 min, preferably in the range from 0.5 to 9.0 g/10 min and more preferably in the range from 0.7 to 6.0 g/10 min; and/or

component b2) has a MFR2 (230°C, 2.16 kg) determined according to ISO 1133 in the range from 0.5 to 14.0 g/10 min, preferably in the range from 0.7 to 11.0 g/10 min and more preferably in the range from 0.9 to 8.0 g/10 min; and/or

the C6-content in component b1) based on the overall weight of component b1) is in the range from 0.1 to 4.0 wt.-%, preferably in the range from 0.5 to 3.5 wt.-% and more preferably in the range from 0.8 to 3.0 wt.-%; and/or

the C6-content in component b2) based on the overall weight of component b2) is in the range from 4.0 to 15.0 wt.-%, preferably in the range from 5.0 to 13.0 wt.-% and more preferably in the range from 6.0 to 12.0 wt.-%; and/or

the content of component b1) in component B) is from 35 to 65 wt.-% and preferably from 40 to 60 wt.-%; and/or

the content of component b2) in component B) is from 35 to 65 wt.-% and preferably from 40 to 60 wt.-%.

7. The polymer composition according to any one of the preceding claims, characterized in that,

component C) is a plastomer and has

a density in the range from 0.860 to 0.930 g/cm3, preferably in the range from 0.865 to 0.920 g/cm3 and more preferably in the range from 0.868 g/cm3; and/or

a MFR2 (190°C, 2.16 kg) determined according to ISO 1133 in the range from 0.1 to 40.0 g/10 min, preferably from 0.4 to 32.0 g/10 min and more preferably in the range from 0.5 to 1.5 g/10 min; or

component (C) is a heterophasic polypropylene copolymer and has

a MFR2 (230°C, 2.16 kg) determined according to ISO 1133 in the range from 1.0 to 10.0 g/10 min, preferably from 1.5 to 8.0 g/10 min and more preferably in the range from 2.0 to 7.0 g/10 min; or

component C) has a xylene soluble content (XCS) based on the overall weight of component C) in the range from 10.0 to 30.0 wt.-%, preferably in the range from 12.0 to 25.0 wt.-% and more preferably in the range from 14 to 20 wt.-%; and/or

component C) has an ethylene content of the xylene soluble fraction C2 (XCS) based on the overall weight of component C) in the range from 35.0 to 70.0 wt.-%, preferably from 40.0 to 65.0 wt.-% and more preferably in the range from 45.0 to 60.0 wt.-%; and/or

component C) has a xylene cold soluble fraction (XCI) based on the overall weight of component C) in the range from 70.0 to 90.0 wt.-%, preferably from 75.0 to 88.0 wt.-% and more preferably in the range from 80.0 to 86.0 wt.-%.

8. The polymer composition according to any one of the preceding claims, characterized in that,

component A) is a recycled material, which is preferably recovered from waste plastic material derived from post-consumer and/or post-industrial waste; and/or

the polymer composition comprises at least one additive, preferably selected from the group consisting of slip agents, UV-stabiliser, pigments, antioxidants, additive carriers, nucleating agents and mixtures thereof, whereby these additives preferably are present in 0 to 5 wt.-% and more preferably in 0.1 to 4 wt.-% based on the overall weight of the polymer composition.

9. The polymer composition according to any one of the preceding claims, characterized in that,

said polymer composition has a higher Charpy Notched Impact Strength measured according to ISO 179-1eA at 23°C, preferably at least 10 % higher, more preferably from 10 to 25 % higher and even more preferably at least 25 % higher than the same polymer composition without components B) and C); and

has at the same time a Tensile Modulus measured according to IS0527-2 of at least 800 MPa and preferably in the range from 800 to 1000 MPa.

10. The polymer composition according to any one of the preceding claims, characterized in that,

component B) is an in-reactor blend obtained by a sequential polymerization process in at least two reactors connected in series, said sequential polymerization process preferably comprises the steps of

(i) polymerizing in a first reactor being a slurry reactor, preferably a loop reactor, propylene and 1 -hexene, obtaining a first random propylene copolymer b1),

(ii) transferring said first random propylene copolymer b1) and unreacted

comonomers of the first reactor in a second reactor being a gas phase reactor,

(iii) feeding to said second reactor propylene and 1 -hexene,

(iv) polymerizing in said second reactor and in the presence of said first random propylene copolymer b1) propylene and 1 -hexene obtaining a second random propylene copolymer b2), said first random propylene copolymer b1) and said second random propylene copolymer b2) form component B),

wherein further

in the first reactor and second reactor the polymerization takes place in the presence of a solid catalyst system, said solid catalyst system (SCS) comprises a single-site catalyst.

1 1. The polymer composition according to any one of the preceding claims, characterized in that,

said polymer composition consists of the following components:

A) 60 to 89 wt.-% based on the overall weight of the polymer composition of a

polymer blend, comprising

a1) 55 to 90 wt.-% of polypropylene;

a2) 10 to 45 wt.-% of polyethylene;

B) 8 to 22 wt.-% based on the overall weight of the polymer composition of a

copolymer of propylene and 1-hexene, comprising

b1) 30 to 70 wt.-% of a first random copolymer of propylene and 1 -hexene; and b2) 30 to 70 wt.-% of a second random copolymer of propylene and 1 -hexene having a higher 1 -hexene content than the first random propylene copolymer b1); and

C) 3 to 7 wt.-% based on the overall weight of the polymer composition of a

plastomer made of ethylene and 1-octene having a density in the range from 0.860 to 0.930 g/cm3 and a MFR2 (190°C, 2.16 kg) determined according to ISO 1133 in the range from 0.1 to 40.0 g/10 min; or

12 to 18 wt.-% based on the overall weight of the polymer composition of a heterophasic polypropylene copolymer comprising

c1) 70.0 to 90.0 wt.-% of a crystalline polypropylene matrix; and

c2) 10.0 to 30.0 wt.-% of an amorphous propylene-ethylene copolymer comprising 35.0 to 70.0 wt.-% of ethylene;

having a MFR2 (230°C, 2.16 kg) determined according to ISO 1133 in the range from 1.0 to 10.0 g/10 min;

with the provisos that

• component A) has a MFR2 (230°C, 2.16 kg) determined according to ISO

1133 in the range from 2.0 to 25.0 g/10 min;

• component B) has a MFR2 (230°C, 2.16 kg) determined according to ISO

1133 in the range from 0.8 to 5.0 g/10 min

• component B) has a xylene soluble content (XCS) based on the overall weight of component B) in the range from 10 to 28 wt.-%;

• the 1 -hexene content in component B) is in the range from 3.5 to 7.2 wt.-%.

12. Use of component B) as described in claims 1 , 4, 6 and component C) as described in claims 1 , 2 and 7 for compatibilizing a polymer blend A) as described in claims 1 , 4 and 8.

13. Use according to claim 12, characterized in that,

the ratio between component B) and the polymer blend A) is in the range from 1 : 20 to 1 : 3 and preferably in the range from 1 : 6 to 1 : 10; and/or

the ratio between component C) and the polymer blend A) is in the range from 1 : 30 to 1 : 8 and preferably in the range from 1 : 12 to 1 : 22 when component C) is a plastomer; or

the ratio between component C) and the polymer blend A) is in the range from to 1 : 3 to 1 : 15 and preferably in the range from 1 : 4 to 1 : 7 when component C) is a heterophasic polypropylene copolymer; and/or

the ratio between component C) and the polymer blend B) is in the range from 1 : 1.5 to 1 : 4 and preferably in the range from 1 : 1.8 to 1 : 2.5 when component C) is a plastomer; or

the ratio between component B) and the polymer blend C) is in the range from to 1 : 1 to 1 : 3 and preferably in the range from 1 : 1.3 to 1 : 1.7 when component C) is a heterophasic polypropylene copolymer.

14. Use according to claim 12 or 13, characterized in that,

the Charpy Notched Impact Strength measured according to ISO 179-1eA at 23°C of the polymer blend A) is increased, preferably by at least 10 %, more preferably by 10 to 25 % and even more preferably by at least 25 % and maintaining at the same time the Tensile Modulus measured according to IS0527-2 of the polymer blend A) at least 800 MPa, preferably from 800 to 1000 MPa.

15. Process for compatibilizing the components of a polymer blend A) as described in claims 1 , 3 and 6 comprising the steps of

(IV) providing the polymer blend A) as described in claims 1 , 4 and 8;

(V) adding component B) as described in claims 1 , 4 and 6 and component C) as described in claims 1 , 2 and 7;

(VI) mixing components A), B) and C) to obtain a compatibilized polymer

composition.

16. Process according to claim 15, characterized in that,

the polymer composition obtained after step (III) has a higher Charpy Notched Impact Strength measured according to ISO 179-1eA at 23°C, preferably at least 10 % higher, more preferably 10 to 25 % higher and more preferably at least 25 % higher than the polymer blend A) provided in step (I) composition without component B); and has at the same time a Tensile Modulus measured according to IS0527-2 of at least 800 MPa and preferably in the range from 800 to 1000 MPa.

17. Article comprising a polymer composition according to any one of claims 1 to 11.

18. Film, pipe, extrusion blow molded or injection molded article comprising more than 80 wt.-% of a polymer composition according to any one of claims 1 to 11.