WO2020169548A1

WO2020169548A1 - Polyolefin compositions and process to produce such compositions by the addition of coupling agents

Info

Publication number: WO2020169548A1
Application number: PCT/EP2020/054146
Authority: WO
Inventors: Thierry Coupin
Original assignee: Total Research & Technology Feluy
Priority date: 2019-02-18
Filing date: 2020-02-18
Publication date: 2020-08-27

Abstract

The disclosure relates to a process to produce a polyolefin composition comprising a blend of polyethylene and polypropylene and to said polyolefin compositions. The process comprises the steps of: - providing a component A, wherein component A is one or more polyethylenes; - providing a component B, wherein component B is one or more polypropylenes; - providing a component C, wherein component C is one or more epoxy functionalized polymers; - providing a component H, wherein component H is one or more grafted and/or modified polyolefins selected from acid-grafted polyolefins and/or anhydride- modified polyolefins; wherein the polyolefin is selected from polyethylene and/or polypropylene; and wherein component H has an MI2 of at least 50 g/10 min as determined according to ISO 1133:1997 and; - melt-blending the said components to form a polyolefin composition.

Description

POLYOLEFIN COMPOSITIONS AND PROCESS TO PRODUCE SUCH COMPOSITIONS

BY THE ADDITION OF COUPLING AGENTS

TECHNICAL FIELD

The disclosure relates to a process for producing polyolefin compositions from polyethylene and polypropylene blends, wherein the polyolefin compositions have improved mechanical properties and to the polyolefin compositions obtained by such process. The disclosure also relates to a process for recycling waste thermoplastic polyolefin materials, comprising a blend of polyethylene and polypropylene, to obtain polyolefin compositions with good mechanical properties and to the polyolefin compositions obtained by said process.

TECHNICAL BACKGROUND

Blends of polyethylene (PE) and polypropylene (PP) have always been the subject of intense research for encouraging polymer waste recycling while producing new materials for specific applications in a sustainable way. However, being thermodynamically immiscible, these polyolefins form a binary system that usually exhibits lower performances compared with those of the homopolymers. Many studies were carried out to better understand the PE/PP blend compatibilization for developing high-performance and cost-effective products. Both reactive and non-reactive compatibilization promote brittle to ductile transition for PE/PP blends. However, the final products do not usually meet the requirements for the current high demanding commercial applications. Therefore, further PE/PP blend modifications with reinforcing filler either synthetic or natural, proved to be a good method for manufacturing high-performance reinforced polymer blend composites with superior and tailored properties.

WO2017/199202 relates to a process for recycling waste thermoplastic polymeric material by reacting, at the molten state, said waste thermoplastic polymeric material with an organic compound containing one or more carbon-carbon double bonds. The reaction takes place in the presence of a free radical initiator. An increase of the molecular weight of the recycled polymers can be obtained and may be controlled by predetermined amounts and relative ratios between mono- or polyunsaturated functional compounds and free-radical initiators.

The use of recycled resin as a raw material for acid modified resins to accomplish an upgrade recycling of plastic wastes has been studied by Yuta Sunaga et al. in “Profitable Mass- Production of Acid-Modified Recovered Resins for Value-Added Mechanical Recycling as a Compatibilizer for Composites” ACS Sustainable Chem. Eng., 2018, 6 (9), pp 121 10-12118. In this study, the polypropylene-rich recovered resin was subjected to acid modification with maleic anhydride (MAH) and an organic peroxide. The obtained acid-modified recovered resins were used as compatibilizers for mass-production of wood/plastic composite (WPC).

US2015/0104597 relates to a thermoplastic composition comprising a blend of polypropylene and polyethylene, an ethylene epoxide copolymer and an ethylene/propylene copolymer grafted or copolymerized with a carboxylic acid or a derivative thereof. This document teaches the advantage of the ethylene/propylene copolymer being a rubber in order to improve the impact resistance or the impact strength of a recycled PE/PP blend. However, there is a need to further improve the balance of mechanical properties obtained on such compositions.

Thus, it is an object of the disclosure to provide polyolefin compositions comprising polyethylene and polypropylene having improved balance of mechanical properties, such as an improved elongation at break and an improved impact resistance, articles made from such compositions and a process to produce such compositions. With preference, it is an object of the disclosure to provide polyolefin compositions comprising polyethylene and polypropylene having improved balance of mechanical properties, selected from elongation at break, impact resistance and tensile modulus, articles made from such compositions and a process to produce such compositions.

It is also an object of the disclosure to provide polyolefin compositions comprising at least 50 wt.% of recycled polyolefins comprising polyethylene and polypropylene, wherein the compositions have improved balance of mechanical properties, such as improved impact resistance and improved elongation at break; articles made from such compositions and a process to produce such compositions. Wth preference, it is an object of the disclosure to provide polyolefin compositions comprising at least 50 wt.% of recycled polyolefins comprising polyethylene and polypropylene, wherein the compositions have improved balance of mechanical properties, selected from impact resistance, elongation at break and tensile modulus; articles made from such compositions and a process to produce such compositions.

Summary

According to a first aspect, the disclosure provides a process to produce a polyolefin composition comprising a blend of polyethylene and polypropylene remarkable in that it comprises the steps of:

providing a component A, wherein component A is one or more polyethylenes;

providing a component B, wherein component B is one or more polypropylenes;

providing a component C, wherein component C is one or more epoxy functionalized polymer;

providing a component H, wherein component H is one or more grafted and/or modified polyolefins selected from acid-grafted polyolefins and/or anhydride-modified polyolefins; wherein the polyolefin is selected from polyethylene and/or polypropylene; and wherein component H has an MI2 of at least 50 g/10 min as determined according to ISO 1 133: 1997 under a load of 2.16 kg and at 190°C when the polyolefin is polyethylene or at 230°C when the polyolefin is or comprises polypropylene;

melt-blending the said components to form a polyolefin composition.

Surprisingly it has been found that it was possible to produce polyolefin compositions comprising polyethylene and polypropylene having improved mechanical properties by grafting at least one of the polyethylene and/or the polypropylene with an anhydride or an acid, and by melt-blending them with a coupling agent being an epoxy functionalized polymer. The grafting agent and the coupling agent form a compatibilizer composition that can be prepared in situ during the melt-blending step. It has been shown, the polyolefin compositions show improved elongation at break and improved impact properties. It has been shown, the polyolefin compositions show improved balance of properties selected from elongation at break, impact properties and tensile modulus. The elongation at break can be doubled compared to the same polyolefin composition devoid of the disclosed compatibilizer composition. When the polyolefins components are already grafted with an anhydride (such as maleic anhydride) and/or with an acid (such as acrylic acid), the disclosure provides the addition of a coupling agent being one or more epoxy functionalized polymers to prepare the composition.

It is noted that US6569947 describes a maleic anhydride-modified ethylene polymer/ ionomer/ high-density polyethylene blend having improved impact resistance (e.g., increased low- temperature Izod impact). This was achieved by the addition of a maleic anhydride grafted high-density polyethylene derived polymer (e.g., MAN-g-HDPE, MAN-g-VLDPE, MAN-g-EPR, MAN-g-EPDM, and the like) to ionomer and to high-density polyethylene during blending. However, this document is silent regarding the possibility to improve the impact resistance in polyolefins blends comprising a mixture of polyethylene and polypropylene either from virgin or recycled resins. This document is also silent regarding the possibility to improve the strain at break for PE/PP blends, and to the possibility to use recycled resins.

In a preferred embodiment, component C is one or more diepoxy functionalized polymers.

In a preferred embodiment, component C is selected from:

one or more diepoxy polyethylene glycols; and/or

one or more ethylene - acrylic ester - glycidyl methacrylate terpolymers.

In a preferred embodiment, component H is one or more maleic anhydride-modified polypropylenes and component C is one or more ethylene - acrylic ester - glycidyl methacrylate terpolymers. In an embodiment, the content of component C ranges from 0.5 to 15 wt.% based on the total weight of the polyolefin composition, preferably from 0.6 to 10.0 wt.%, more preferably from 0.7 wt.% to 8.0 wt.%, even more preferably from 0.8 wt.% to 7.0 wt.%, most preferably from 0.9 wt.% to 6.0 wt.%, even most preferably from 1.0 wt.% to 5.0 wt.

In an embodiment, the content of component H ranges from 0.5 to 15 wt.% based on the total weight of the polyolefin composition, preferably from 0.6 to 10.0 wt.%, more preferably from 0.7 wt.% to 8.0 wt.%, even more preferably from 0.8 wt.% to 7.0 wt.%, most preferably from 0.9 wt.% to 6.0 wt.%, even most preferably from 1.0 wt.% to 5.0 wt.

For example, the weight ratio of component C to component H is ranging between 5:1 to 1 :5, preferably between 3: 1 to 1 :3, more preferably between 2: 1 to 1 :2 and most preferably is 1 : 1.

In an embodiment, component C has a weight average molecular weight (Mw) of at least 10,000 g/mol, preferably at least 12,000 g/mol, more preferably at least 15,000 g/mol, even more preferably at least 20,000 g/mol, most preferably at least 30,000 g/mol, or at least 40, 000 g/mol, or at least 45,000 g/mol, or at least 50,000 g/mol, or at least 55,000 g/mol, or of at least 60,000 g/mol.

In an embodiment, component C has a number average molecular weight (Mn) of at least 2.400 g/mol, more preferably at least 2,500 g/mol, even more preferably at least 3,000 g/mol, most preferably at least 5,000 g/mol, even most preferably at least 8,000 g/mil, or at least 10,000 g/mol, or at least 12,000 g/mol, or at least 130,00 g/mol, or at least 15,000 g/mol.

In an embodiment, component H has a weight average molecular weight (Mw) of at least 10,000 g/mol, preferably at least 12,000 g/mol, more preferably at least 15,000 g/mol, even more preferably at least 20,000 g/mol, most preferably at least 30,000 g/mol, or at least 40, 000 g/mol, or at least 45,000 g/mol, or at least 50,000 g/mol, or at least 55,000 g/mol, or at least 60,000 g/mol.

In an embodiment, component H has a number average molecular weight (Mn) of at least 2.400 g/mol, more preferably at least 2,500 g/mol, even more preferably at least 3,000 g/mol, most preferably at least 5,000 g/mol, even most preferably at least 8,000 g/mil, or at least 10000 g/mol, or at least 12000 g/mol, or at least 13000 g/mol, or at least 15000 g/mol.

For example, component C and/or component H have a weight average molecular weight (Mw) of at least 10,000 g/mol and/or a number average molecular weight (Mn) of at least 2,400 g/mol.

For example, component H has an MI2 of at least 80 g/10 min as determined according to ISO 1133: 1997 under a load of 2.16 kg and at 190°C when the polyolefin is polyethylene or at 230°C when the polyolefin is or comprises polypropylene; preferably of at least 100 g/10 min, more preferably of at least 120 g/10 min; and most preferably of at least 140 g/10 min.

For example, component H has an MI2 of at most 500 g/10 min as determined according to ISO 1133: 1997 under a load of 2.16 kg and at 190°C when the polyolefin is polyethylene or at 230°C when the polyolefin is or comprises polypropylene; preferably of at most 300 g/10 min; more preferably of at most 250 g/10min, most preferably of at most 200 g /10 min, and even most preferably at most 175 g/10 min.

For example, the polyolefin of component H is or comprises a polypropylene homopolymer and/or a random copolymer of propylene and at least one comonomer.

For example, the polyolefin of component H is or comprises a polyethylene homopolymer and/or a random copolymer of ethylene and at least one comonomer. For example, the polyolefin of component H is or comprises of one or more selected from a polypropylene homopolymer, a random copolymer of propylene and at least one comonomer, a polyethylene homopolymer and a random copolymer of ethylene and at least one comonomer.

The components C and H may define a compatibilizer composition, said compatibilizer composition can be prepared before the step of melt-blending the components to form a polyolefin composition, or during said step of melt-blending the components to form a polyolefin composition. With preference, when the compatibilizer is prepared before the step of melt-blending the components to form a polyolefin composition, the component C and the component H are dry blended and provided together as a composition. Wth preference, when the compatibilizer is prepared in situ, during the step of melt-blending the components to form a polyolefin composition, the components C and H are provided separately.

In an embodiment, the total content of both component C and component H ranges from 1 to 30 wt.% based on the total weight of the polyolefin composition; preferably from 2 to 25 wt.%, more preferably from 3 to 20 wt.%, even more preferably from 4 wt.% to 15 wt.%, most preferably from 5 wt.% to 12 wt.%, or from 6 wt.% to 10 wt.%.

In an embodiment, the total content of both component C and component H is more than 4 wt.% based on the total weight of the polyolefin composition, preferably more than 4.5 wt.% even more preferably more than 5 wt.%.

In an embodiment, component H is one or more grafted and/or modified polyolefins selected from acid-grafted polypropylene, acid-grafted polyethylene, anhydride-modified polypropylene, and anhydride-modified polyethylene. With preference, component H is one or more grafted and/or modified polyolefins selected from acrylic acid-grafted polyolefin, fumaric acid-grafted polyolefin, maleic acid-grafted polyolefin, methacrylic acid-grafted polyolefin, nadic acid-grafted polyolefin, citraconic acid- grafted polyolefin, itaconic acid-grafted polyolefin, acrylic anhydride-modified polyolefin, fumaric anhydride-modified polyolefin, maleic anhydride-modified polyolefin, methacrylic anhydride-modified polyolefin, nadic anhydride-modified polyolefin, citraconic anhydride- modified polyolefin, itaconic anhydride-modified polyolefin; wherein the polyolefin is selected from polyethylene and/or polypropylene.

In a preferred embodiment, component H is one or more maleic anhydride-modified polyolefins selected from one or more maleic anhydride-modified polyethylenes and/or one or more maleic anhydride-modified polypropylenes.

In a preferred embodiment, the component A and/or the component B are recycled resins selected from post-consumer resins (PCR) and/or post-industrial resins (PIR); with preference:

the total content of the recycled resins (RRT) in the polyolefin composition ranges from 50 to 99 wt.% based on the total weight of the polyolefin composition; and/or the components A and B are provided separately as a polyethylene recycled resin (rPE), and a polypropylene recycled resin (rPP); or the component A and B are provided together as a polyolefin recycled resin (rPO).

In particular, when both components A and B are recycled resins, the process preferably further comprises, before the step of melt blending the components to form a polyolefin composition, one or more steps selected from:

providing a component D being at least one virgin polyethylene, with preference component D has an MI2 ranging from 0.10 to 70.0 g/10 min as determined according to ISO 1133: 1997 conditions D, at a temperature of 190°C and under a load of 2.16 kg; and/or

providing a component E being at least one virgin polypropylene, with preference component E has an MI2 ranging from 1.0 to 200.0 g/10 min as determined according to ISO 1 133: 1997 conditions M, at a temperature of 230°C and under a load of 2.16 kg.

With preference, one or more of the following embodiments can be used to better define the component A to be used in the process: Component A is a virgin resin, or component A is a recycled polyethylene resin (rPE) selected from post-consumer resin (PCRA) and/or post-industrial resins (PI RA).

Component A is a recycled resin selected from one or more polyethylene post consumer resins (PCR-PE), polyethylene post-industrial resins (PIR-PE), polyolefin post-consumer resins (PCR-PO), and polyolefin post-industrial resins (PIR-PO).

The content of component A ranges from 10 to 90 wt.% based on the total weight of the polyolefin composition, preferably, from 15 to 85 wt.%, or from 20 to 80 wt.%, more preferably from 25 wt.% to 75 wt.% and even more preferably from 30 to 70 wt.%. Component A has an MI2 ranging from 0.10 to 70.0 g/10 min as determined according to ISO 1133: 1997 conditions D, at a temperature of 190°C and under a load of 2.16 kg; preferably from 0.15 to 15.0 g/10 min.

Component A has a density ranging from 0.820 to 0.980 g/cm³ as determined according to ISO 1183 at a temperature of 23°C.

With preference, one or more of the following embodiments can be used to better define the component B to be used in the process:

Component B is a virgin resin or component B is a recycled polypropylene resin (rPP) selected from post-consumer resin (PCRB) and/or post-industrial resins (PI RB).

Component B is a recycled resin selected from one or more polypropylene post consumer resins (PCR-PP), polypropylene post-industrial resins (PIR-PP), polyolefin post-consumer resins (PCR-PO), and polyolefin post-industrial resins (PIR-PO).

The content of component B ranges from 10 to 90 wt.% based on the total weight of the polyolefin composition, preferably, from 15 to 85 wt.%, or from 20 to 80 wt.%, more preferably from 25 wt.% to 75 wt.% and even more preferably from 30 to 70 wt.%. Component B has an MI2 ranging from 1.0 to 200.0 g/10 min as determined according to ISO 1 133: 1997 conditions M, at a temperature of 230°C and under a load of 2.16 kg; preferably from 5.0 to 50.0 g/10 min.

Component B has a density ranging from 0.870 to 0.946 g/cm³ as determined according to ISO 1183 at a temperature of 23°C, preferably ranging from 0.890 to 0.940 g/cm³; more preferably ranging from 0.900 to 0.930 g/cm³.

For example, the component A and the component B are in a weight ratio ranging between 5:1 to 1 :5, preferably between 3:1 to 1 :3, more preferably between 2:1 to 1 :2 and most preferably is 1 :1.

With preference, components A and B are provided together as a recycled polyolefin resin (rPO) selected from polyolefin post-consumer resin (PCR-PO) and/or polyolefin post-industrial resins (PIR-PO), and one or more of the following embodiments can be used to better define the recycled polyolefin resin (rPO) to be used in the process: The recycled polyolefin resin (rPO) comprises at least 30 wt.% of polyethylene based on the total weight of the recycled polyolefin resin and/or comprises at least 30 wt.% of polypropylene based on the total weight of the recycled polyolefin resin.

In a preferred embodiment, before the step of melt blending the components to form a polyolefin composition, the process further comprises a step of providing a component F being one or more fillers, and the step of melt-blending the components to form a polyolefin composition comprises melt-blending component F with the other components to form the polyolefin composition. With preference, one or more of the following embodiments can be used to better define the component F to be used in the process:

The content of component F ranges from 0 to 50 wt.% based on the total weight of the polyolefin composition; preferably from 0.1 to 50.0 wt.%, more preferably from 0.2 wt.% to 40.0 wt.%, even more preferably from 0.5 wt.% to 30.0 wt.%, most preferably from 1.0 wt.% to 20 wt.%, even most preferably from 1.5 wt.% to 15.0 wt.%, or from 2.5 wt.% to 12.5 wt.%, or from 5.0 wt.% to 10.0 wt.%

Component F comprises one or more reinforcement materials selected from talc mineral filler, wollastonite, calcium carbonate, modified calcium carbonate, coated calcium carbonate, glass fibres, bamboo fibres, flax fibres, hemp fibres, carbon black, carbon nanotubes, graphene nanotubes, and any mixture thereof; with preference, component F comprises one or more reinforcement materials selected from talc, glass fibres and carbon nanotubes; more preferably, component F comprises one or more reinforcement materials selected from glass fibres and carbon nanotubes.

In a preferred embodiment, before the step of melt blending the components to form a polyolefin composition, the process further comprises a step of providing a component G being one or more elastomers, and the step of melt-blending the components to form a polyolefin composition comprises melt-blending the component G with the other components to form the polyolefin composition. Wth preference, one or more of the following embodiments can be used to better define the component G to be used in the process:

The content of component G ranges from 0 to 10 wt.% based on the total weight of the polyolefin composition; preferably from 0.1 to 10.0 wt.%, more preferably from 0.2 wt.% to 9.8 wt.%, even more preferably from 0.5 wt.% to 9.5 wt.%, most preferably from 1.0 wt.% to 9.3 wt.%, even most preferably from 1.5 wt.% to 9.1 wt.%, or from 2.5 wt.% to 9.0 wt.%, or from 5.0 wt.% to 8.5 wt.%.

The component G, being one or more elastomers, has an MI2 ranging from 0.5 to 5.0 g/10 min as determined according to ISO 1 133: 1997 conditions D, at a temperature of 190 °C and under a load of 2.16 kg, preferably the component G has an MI2 of at most 4.5 g/10 min, more preferably of at most 4.0 g/10 min, even more preferably of at most 3.5 g/10 min, most preferably of at most 3.0 g/10 min, even most preferably of at most 2.5 g/10 min or of at most 2.0 g/10 min.

Component G is selected from elastomeric copolymers of ethylene with 1-octene, elastomeric copolymers of ethylene with 1 -butene; elastomeric copolymers of ethylene with propene, and any mixture thereof; and/or from SIS (Styrene isoprene styrene block copolymers), SEPS (Hydrogenated styrene isoprene styrene block copolymers), SBS (Styrene butadiene styrene block copolymers), SEBS (Hydrogenated styrenic butadiene copolymers), SBSS (Styrene butadiene styrene styrene block copolymers), and any mixture thereof.

The steps of providing components F and G, when both conducted, can be performed in any order or simultaneously.

In preferred embodiments, the process is devoid of a step of addition of peroxides.

In a preferred embodiment, component H is or comprises anhydride-modified polyolefin; wherein the polyolefin is selected from polyethylene and/or polypropylene, and the process further comprises a step of providing water, wherein water is provided before the step of melt blending of the components to form a polyolefin composition.

With preference, the content of the water melt-blended within the polyolefin composition is preferably ranging from 0.1 to 10.0 wt.% based on the total weight of the polyolefin composition without water; preferably 0.5 to 5.0 wt.%, more preferably from 1.0 to 3.0 wt.%.

According to a second aspect, the disclosure provides a polyolefin composition, remarkable in that it comprises

a component A being of one or more polyethylenes,

a component B being one or more polypropylenes,

a component C being one or more epoxy functionalized polymers, and

a component H being one or more grafted and/or modified polyolefins selected from acid-grafted polyolefins and/or anhydride-modified polyolefins; wherein the polyolefin is selected from polyethylene and/or polypropylene, and wherein component H has an MI2 of at least 50 g/10 min as determined according to ISO 1133:1997 under a load of 2.16 kg and at 190°C when the polyolefin is polyethylene or at 230°C when the polyolefin is or comprises polypropylene.

Preferably the polyolefin composition is produced by a process according to the first aspect. Wth preference, the total content of the component C and the component H ranges from 1 to 30 wt.% based on the total weight of the polyolefin composition, preferably from 2 to 20 wt.%. For example, the component A and the component B are in a weight ratio ranging between 5:1 to 1 :5, preferably between 3:1 to 1 :3, more preferably between 2:1 to 1 :2 and most preferably is 1 :1.

In a preferred embodiment, the polypropylene (i.e. component B) and the polyethylene (i.e. component A) are in a weight ratio of 1 : 1 and in co-continuous phases.

In another embodiment, the content of the polyethylene (i.e. component A) is at least 60 wt.% based on the total weight of the polyolefin composition and the polypropylene (i.e. component B) has a droplet dispersion within the polyethylene (i.e. component A).

In another embodiment, the content of the polypropylene (i.e. component B) is at least 60 wt.% based on the total weight of the polyolefin composition and the polyethylene (i.e. component A) has a droplet dispersion within the polypropylene (i.e. component B).

According to a third aspect, the disclosure provides the use of the polyolefin composition obtained by the process according to the first aspect, or of the polyolefin composition of the second aspect, to make an article in a process selected from 3D-printing, extrusion, blow moulding, injection, injection blow moulding, injection stretch blow moulding, rotomoulding, extrusion and thermoforming.

According to a fourth aspect, the disclosure provides an article made from the polyolefin composition obtained by the process according to the first aspect, or by the polyolefin composition of the second aspect, preferably:

the article is a thermoformed article or a moulded article selected from injection moulded article, compression moulded article, rotomoulded article, injection blow moulded article, and injection stretch blow moulded article, and/or

the article is selected from the group consisting of automobile parts, non-food packaging, retort packaging, housewares, caps, closures, media packaging and medical devices.

According to a fifth aspect, the disclosure provides the use of a component C being one or more coupling agents in a polyolefin composition comprising a component A being one or more polyethylene, a component B being one or more polypropylenes and a component H being one or more grafted and/or modified polyolefins selected from acid-grafted polyolefins and/or anhydride-modified polyolefins; wherein the polyolefin is selected from polyethylene and/or polypropylene; and wherein the component C is selected from one or more epoxy functionalized polymers. According to a sixth aspect, the disclosure provides a compatibilizer composition for use in a process according to the first aspect; the compatibilizer composition comprising a blend of: a component H being one or more grafted and/or modified polyolefins selected from acid-grafted polyolefins and/or anhydride-modified polyolefins; wherein the polyolefin is selected from polyethylene and/or polypropylene; and

a component C being one or more epoxy functionalized polymers; with preference diepoxy functionalized polymer.

In a preferred embodiment, component C is selected from:

one or more diepoxy polyethylene glycols; and/or

one or more ethylene - acrylic ester - glycidyl methacrylate terpolymers.

In a preferred embodiment, the component H is one or more maleic anhydride-modified polypropylenes and the component C is one or more ethylene - acrylic ester - glycidyl methacrylate terpolymers.

According to a seventh aspect, the disclosure provides the use of a compatibilizer composition according to the sixth aspect in a polyolefin composition comprising a component A being one or more polyethylenes, a component B being one or more polypropylenes.

In a preferred embodiment, the use comprises the addition of the compatibilizer composition in a content ranging from 1 to 30 wt.% based on the total weight of the polyolefin composition; preferably from 2 to 25 wt.%, more preferably from 3 to 20 wt.%, even more preferably from 4 wt.% to 15 wt.%, most preferably from 5 wt.% to 10 wt.%

DETAILED DESCRIPTION

For the purpose of the disclosure, the following definitions are given.

The terms "comprising", "comprises" and "comprised of" as used herein are synonymous with "including", "includes" or "containing", "contains", and are inclusive or open-ended and do not exclude additional, non-recited members, elements or method steps. The terms "comprising", "comprises" and "comprised of" also include the term“consisting of”.

The recitation of numerical ranges by endpoints includes all integer numbers and, where appropriate, fractions subsumed within that range (e.g. 1 to 5 includes 1 , 2, 3, 4 when referring to, for example, a number of elements, and can also include 1.5, 2, 2.75 and 3.80, when referring to, for example, measurements). The recitation of endpoints also includes the recited endpoint values themselves (e.g. from 1.0 to 5.0 includes both 1.0 and 5.0). Any numerical range recited herein is intended to include all sub-ranges subsumed therein.

The reference throughout this specification to“one embodiment” or“an embodiment” means that a particular feature, structure or characteristic described in connection with the embodiment is included in at least one embodiment of the present disclosure. The particular features, structures, characteristics or embodiments may be combined in any suitable manner, as would be apparent to a person skilled in the art from this disclosure, in one or more embodiments. Furthermore, while some embodiments described herein include some but not other features included in other embodiments, combinations of features of different embodiments are meant to be within the scope of the disclosure and form different embodiments, as would be understood by those in the art.

Unless otherwise defined, all terms used in disclosing the disclosure, including technical and scientific terms, have the meaning as commonly understood by one skilled in the art to which this disclosure belongs. By means of further guidance, definitions for the terms used in the description are included to better appreciate the teaching of the present disclosure.

As used herein, the terms“melt blending” involve the use of shear force, extensional force, compressive force, ultrasonic energy, electromagnetic energy, thermal energy or combinations comprising at least one of the foregoing forces or forms of energy and is conducted in a processing equipment wherein the aforementioned forces are exerted by a single screw, multiple screws, intermeshing co-rotating or counter-rotating screws, non intermeshing co-rotating or counter-rotating screws, reciprocating screws, screws with pins, barrels with pins, rolls, rams, helical rotors, or combinations comprising at least one of the foregoing. Melt blending may be conducted in machines such as single or multiple screw extruders, Buss kneader, Eirich mixers, Henschel, helicones, Ross mixer, Banbury, roll mills, moulding machines such as injection moulding machines, vacuum forming machines, blow moulding machines, or the like, or combinations comprising at least one of the foregoing machines. It is generally desirable during melting or solution blending of the composition to impart specific energy of about 0.01 to about 10 kilowatt-hours/kilogram (kW h/kg) to the composition. In a preferred embodiment, melt blending is performed in a twin-screw extruder, such as a Brabender co-rotating twin-screw extruder.

The terms“polypropylene” (PP) and“propylene polymer” may be used synonymously. The term “polypropylene” encompasses homopolymers of propylene as well as copolymers of propylene which can be derived from propylene and one or more comonomers selected from the group consisting of ethylene and C4-C20 alpha-olefins, such as 1 -butene, 1-pentene, 4- methyl-1 -pentene, 1 -hexene, 1-octene, 1-decene, 1-dodecene, 1-tetradecene, 1-hexadecene, 1-octadecene and 1-eicosene.

The terms“polyethylene” (PE) and“ethylene polymer” may be used synonymously. The term “polyethylene” encompasses homopolymers of ethylene as well as copolymers of ethylene which can be derived from ethylene and one or more comonomers selected from the group consisting of C3-C20 alpha-olefins, such as propylene, 1 -butene, 1 -pentene, 4-methyl-1- pentene, 1 -hexene, 1-octene, 1-decene, 1-dodecene, 1-tetradecene, 1-hexadecene, 1- octadecene and 1-eicosene.

The term“copolymer” refers to a polymer which is made by linking a monomer and at least one comonomer in the same polymer chain. The term“homopolymer” refers to a polymer which is made in the absence of comonomer or with less than 0.1 wt.%, more preferably less than 0.05 wt.%, most preferably less than 0.005 wt.% of comonomer based on the total weight of the polymer.

The terms“polypropylene resin” or“polyethylene resin”, as used herein, refer to polypropylene or polyethylene fluff or powder that is extruded, and/or melted and/or pelletized and can be produced through compounding and homogenizing of the polypropylene resin or the polyethylene resin as taught herein, for instance, with mixing and/or extruder equipment. As used herein, the term“polypropylene” may be used as a shorthand for“polypropylene resin”, idem for“polyethylene” that can be used as a shorthand for“polyethylene resin”. The terms “fluff” or“powder” as used herein refer to polypropylene material with the hard catalyst particle at the core of each grain and is defined as the polymer material after it exits the polymerization reactor (or the final polymerization reactor in the case of multiple reactors connected in series).

Under normal production conditions in a production plant, it is expected that the melt index (MI2) will be different for the fluff than for the polyethylene resin or for the polypropylene resin. Under normal production conditions in a production plant, it is expected that the density will be slightly different for the fluff, than for the polyethylene resin or for the polypropylene resin. Unless otherwise indicated, density and melt index for the polyethylene resin or for the polypropylene resin refer to the density and melt index as measured on the polyethylene resin or of the polypropylene resin as defined above.

The terms“virgin polyethylene” are used to denote a polyethylene directly obtained from a polyethylene polymerization plant. The terms“directly obtained” is meant to include that the polyethylene may optionally be passed through a pelletization step or an additivation step or both. The terms“virgin polypropylene” are used to denote a polypropylene directly obtained from a propylene polymerization plant. The terms“directly obtained” is meant to include that the polypropylene may optionally be passed through a pelletization step or an additivation step or both.

The terms “recycled resins” encompasses both Post-Consumer Resins (PCR) and Post- Industrial Resins (PIR).

The terms“Post-Consumer Resin”, which may be abbreviated as“PCR”, is used to denote the components of domestic waste, household waste or end of life vehicle waste. In other words, the PCR are made of recycled products from waste created by consumers.

The terms“Post-Industrial Resin”, which may be abbreviated as“PIR”, is used to denote the waste components from pre-consumer resins during packaging processes. In other words, the PIR are made of recycled products created from scrap by manufacturers.

The terms“polyolefin recycled resin” (rPO),“polyolefin post-consumer resin” (PCR-PO) and “polyolefin post-industrial resin” (PIR-PO) denote recycled materials that are compounds made of high-density polyethylene, low-density polyethylene, linear low-density polyethylene and polypropylene. The content of polypropylene in polyolefin recycled resin is higher than the content of polypropylene in polyethylene post-consumer resins and in post-industrial resins.

As used herein, "blend", "polymer blend" and like terms refer to a composition of two or more compounds, for example, two or more polymers or one polymer with at least one other compound.

The particular features, structures, characteristics or embodiments may be combined in any suitable manner, as would be apparent to a person skilled in the art from this disclosure, in one or more embodiments.

The disclosure provides a process to produce a polyolefin composition comprising a blend of polyethylene and polypropylene remarkable in that it comprises the steps of:

providing a component A, wherein component A is one or more polyethylenes;

providing a component B, wherein component B is one or more polypropylenes;

providing a component C, wherein component C is one or more epoxy functionalized polymers;

providing a component H, wherein component H is one or more grafted and/or modified polyolefins selected from acid-grafted polyolefins and/or anhydride-modified polyolefins; wherein the polyolefin is selected from polyethylene and/or polypropylene; and wherein component H has an MI2 of at least 50 g/10 min as determined according to ISO 1 133: 1997 under a load of 2.16 kg and at 190°C when the polyolefin is polyethylene or at 230°C when the polyolefin is or comprises polypropylene;and

melt-blending the said components to form a polyolefin composition.

According to the disclosure, the components A and B can be selected from virgin resins or from recycled resins. When component A and/or component B are post-consumer resins, they can be submitted to a fine grinding step before being melt-blended, in order to obtain a powder. Indeed, when component A and/or component B are recycled resins, they may be provided in flakes or pellets form. Optionally, component A and/or component B are provided in a powder form. The recycled resins that are provided in flakes form have been collected as waste. If the recycled resins are further extruded and filtered, they are provided in pellets form.

In an embodiment, the step of melt blending is performed with a co-rotating twin-screw extruder. The step of melt blending is performed in an extruder at a screw speed of at least 100 rpm, preferably of at least 120 rpm. For example, the screw speed may range from 150 rpm to 1200 rpm. When component A and/or component B are recycled resins, the step of melt-blending to form a polyolefin composition comprises passing the melted polyolefin composition through one or more screen filters having a mesh size ranging from 40 to 220 microns, preferably from 80 to 200 microns and isolating the filtered polyolefin composition.

Selection of the polyethylene (components A and D)

With preference, component A and/or component D have an MI2 of at most 70.0 g/10 min as determined according to ISO 1133: 1997 conditions D, at a temperature of 190°C and under a load of 2.16 kg, preferably of at most 50.0 g/10 min, more preferably at most 25.0 g/10 min, or at most 20 g/10 min, even more preferably at most 15 g/10 min, most preferably of at most 10.0 g/10 min, even most preferably of at most 5.0 g/10min, or of at most 3.0 g/10 min, or of at most 2.0 g/10 min, or of at most 1.5 g/10 min, or of at most 1.0 g/10 min.

Preferably, component A and/or component D have an MI2 of at least 0.10 g/10 min as determined according to ISO 1133: 1997 conditions D, at a temperature of 190°C and under a load of 2.16 kg, preferably of at least 0.15 g/10 min, more preferably at least 0.20 g/10 min, and even more preferably at least 0.25 g/10 min, or at least 0.30 g/10 min, or at least 0.40 g/10 min, or at least 0.50 g/10 min. With preference, component A and/or component D have an MI2 ranging from 0.10 to 70.0 min as determined according to ISO 1 133: 1997 conditions D, at a temperature of 190°C and under a load of 2.16 kg, preferably from 0.10 to 50.0 g/10 min, more preferably from 0.10 to 25.0 g/10 min, even more preferably from 0.10 to 15 g/10 min, most preferably from 0.10 to 10.0 g/10 min, even most preferably from 0.10 to 5.0 g/10 min, or from 0.10 to 3.0 g/10 min, or from 0.15 to 2.0 g/10 min, or from 0.20 to 1.5 g/10 min, or from 0.25 to 1.0 g/10 min, or from 0.5 to 1.0 g/10 min, or from 0.15 to 15.0 g/10 min.

When component A and/or component D contains two or more polyethylene resins of different melt index, the MI2 to be considered is the MI2 measured on the mixture of said two or more polyethylene resins.

In an embodiment, component A and/or component D has a monomodal molecular weight distribution. In another embodiment, component A and/or component D has a multimodal molecular weight distribution, preferably a bimodal molecular weight distribution. Component A and/or component D may be monomodal or multimodal.

As used herein, the terms“monomodal polyethylene” or“polyethylene with a monomodal molecular weight distribution” refers to polyethylene having one maximum in their molecular weight distribution curve, which is also defined as a unimodal distribution curve. As used herein, the terms“polyethylene with a bimodal molecular weight distribution” or“bimodal polyethylene” refer to polyethylene having a distribution curve being the sum of two unimodal molecular weight distribution curves, and refer to a polyethylene product having two distinct but possibly overlapping populations of polyethylene macromolecules each having different weight average molecular weights.

As used herein, the terms“polyethylene with a multimodal molecular weight distribution” or “multimodal polyethylene” refer to polyethylene with a distribution curve is the sum of at least two, preferably more than two unimodal distribution curves, and refer to a polyethylene product having two or more distinct but possibly overlapping populations of polyethylene macromolecules each having different weight average molecular weights. The multimodal polyethylene can have an“apparent monomodal” molecular weight distribution, which is a molecular weight distribution curve with a single peak and no shoulder. In an embodiment, said polyethylene resin having a multimodal, preferably bimodal, molecular weight distribution can be obtained by physically blending at least two polyethylene fractions.

The density of component A and/or component D ranges from 0.820 g/cm³ to 0.980 g/cm³. Preferably, the polyethylene has a density of at most 0.960 g/cm³. Preferably, the polyethylene has a density of at least 0.850 g/cm³, more preferably of at least 0.900 g/cm³, even more preferably of at least 0.910 g/cm³ and most preferably of at least 0.915 g/cm³. The density is determined according to ISO 1 183 at a temperature of 23 °C.

Component A and/or component D comprises linear low-density polyethylene (LLDPE), low- density polyethylene (LDPE), medium-density polyethylene (MDPE), high-density polyethylene (HDPE), and mixtures thereof.

Component A and/or component D comprises one or more polyethylenes selected from ethylene homopolymers, copolymers of ethylene and at least one comonomer, or mixture thereof. Suitable comonomers comprise but are not limited to aliphatic C3-C20 alpha-olefins. Examples of suitable aliphatic C3-C20 alpha-olefins include propylene, 1 -butene, 1-pentene, 4- methyl-1-pentene, 1 -hexene, 1-octene, 1-decene, 1-dodecene, 1-tetradecene, 1-hexadecene, 1-octadecene and 1-eicosene.

The term“copolymer” refers to a polymer which is made by linking ethylene and at least one comonomer in the same polymer chain. The term“homopolymer” refers to a polymer which is made in the absence of comonomer or with less than 0.1 wt.%, more preferably less than 0.05 wt.%, most preferably less than 0.005 wt.% of comonomer based on the total weight of the polymer.

In case of component A and/or component D is or comprises an ethylene copolymer, it comprises at least 0.1 wt.% of comonomer, preferably at least 1 wt.% based on the total weight of the copolymer. The ethylene copolymer comprises up to 10 wt.% of comonomer based on the total weight of the copolymer, and most preferably up to 6 wt.%. In an embodiment of the disclosure, the comonomer is 1 -hexene.

The content of component A in the polyolefin composition is at least 10 wt.% based on the total weight of the polyolefin composition, preferably at least 15 wt.% or at least 20 wt.%, more preferably at least 25 wt.% or at least 27 wt.% or at least 30 wt.%, even more preferably at least 40 wt.%, most preferably at least 50 wt.%, and even most preferably at least 60 wt.%, or at least 70 wt.%.

The content of component A in the polyolefin composition is at most 90 wt.% based on the total weight of the polyolefin composition, preferably at most 85 wt.% or at most 80 wt.%, more preferably at most 75 wt.% or at most 70 wt.%, even more preferably at most 67 wt.% or at most 65 wt.% or at most 60 wt.%, most preferably at most 50 wt.%, and even most preferably at most 40 wt.%, or at most 30 wt.%.

The content of component D in the polyolefin composition is at least 10 wt.% based on the total weight of the polyolefin composition, preferably at least 15 wt.% or at least 20 wt.%, more preferably at least 25 wt.% or at least 27 wt.% or at least 30 wt.%, even more preferably at least 40 wt.%, most preferably at least 50 wt.%, and even most preferably at least 60 wt.%, or at least 70 wt.%.

The content of component D in the polyolefin composition is at most 90 wt.% based on the total weight of the polyolefin composition, preferably at most 85 wt.% or at most 80 wt.%, more preferably at most 75 wt.% or at most 70 wt.%, even more preferably at most 67 wt.% or at most 65 wt.% or at most 60 wt.%, most preferably at most 50 wt.%, and even most preferably at most 40 wt.%, or at most 30 wt.%.

Non-exhaustive specific examples of commercially available virgin polyethylene resins that can be used as component A and/or component D in the process are:

HDPE 5502 produced by TOTAL, having an MI2 of 0.25 g/10 min and a density of 0.954 g/cm³.

Lumicene Supertough 22ST05 produced by TOTAL, having an MI2 of 0.5 g/10 min and a density of 0.932 g/cm³.

FE 8000 produced by TOTAL, having an MI2 of 0.8 g/10 min and a density of 0.924 g/cm³.

Lumicene M2710EP produced by TOTAL, having an MI2 of 0.9 g/10 min and a density of 0.927 g/cm³.

Q1018N produced by TOTAL, having an MI2 of 1.0 g/10 min and a density of 0.918 g/cm³.

An example of a commercially available stream of polyethylene post-consumer resin (PCR- PE) that can be used as component A (PCR_A) suitable for the process of the disclosure is KWR105M2 marketed by KW Plastics.

The polyethylene post-consumer resin (PCR-PE) that can be used in accordance with the disclosure is preferably selected from HDPE dairy packaging waste.

In a preferred embodiment, the polyethylene recycled resin (rPE) that can be used in accordance with the disclosure comprises less than 10 wt.% based on the total weight of the recycled resin of polymers other than polyethylene. For example, the polyethylene recycled resin may contain up to 10 wt.% of polypropylene based on the total weight of the polyethylene recycled resin (rPE).

The use of a polyethylene recycled resin (rPE and/or rPO) as component A allows the increase of the total content of the recycled resins in the polyolefin composition. The presence of component D in the polyolefin composition is optional. Component D comprises one or more polyethylenes and may be present when component A is a recycled resin selected from a polyethylene post-consumer resin (PCR-PE), a polyolefin post consumer resin (PCR-PO), a polyethylene post-industrial resin (PIR-PE), a polyolefin post industrial resin (PIR-PO), or a mixture thereof.

Selection of the polypropylene (components B and E)

With preference, component B and/or component E have an MI2 of at most 200.0 g/10 min as determined according to ISO 1 133: 1997 conditions M, at a temperature of 230°C and under a load of 2.16 kg, preferably of at most 150.0 g/10 min, more preferably at most 100.0 g/10 min or at most 80.0 g/10 min, even more preferably at most 50.0 g/10 min, most preferably of at most 30.0 g/10 min or at most 25.0 g/10 min, even most preferably of at most 20.0 g/10 min, or of at most 15.0 g/10 min.

Preferably, component B and/or component E has an MI2 of at least 1.0 g/10 min as determined according to ISO 1 133: 1997 conditions M, at a temperature of 230°C and under a load of 2.16 kg, preferably of at least 2.0 g/10 min or at least 3.0 g/10 min, more preferably at least 5.0 g/10 min, even more preferably at least 6.0 g/10 min, most preferably of at least 7.0 and even most preferably of at least 10.0 g/10 min.

Wth preference, component B and/or component E have an MI2 ranging from 1.0 to 200 g/10 min as determined according to ISO 1 133: 1997 conditions M, at a temperature of 230°C and under a load of 2.16 kg, preferably ranging from 1.0 to 1500.0 g/10 min, more preferably ranging from 1.0 to 80.0 g/10 min, even more preferably ranging from 3.0 to 50.0 g/10 min, most preferably ranging from 5.0 to 30.0 g/10 min, or ranging from 6.0 to 25.0 g/10 min, even most preferably ranging from 7.0 to 20.0 g/10 min, or ranging from 10.0 to 15.0 g/10 min, or ranging from 5.0 to 50.0 g/10 min.

When component B and/or component E contains two or more polypropylene resins of different melt index, the MI2 to be considered is the MI2 measured on the mixture of said two or more polypropylene resins.

Preferably, component B and/or component E has a density ranging from 0.870 to 0.946 g/cm³ as determined according to ISO 1183 at a temperature of 23°C, preferably ranging from 0.890 to 0.940 g/cm³; more preferably ranging from 0.900 to 0.930 g/cm³. The density is determined according to ISO 1 183 at a temperature of 23 °C. In an embodiment, component B and/or component E has a monomodal molecular weight distribution. In another embodiment, component B and/or component E has a multimodal molecular weight distribution, preferably a bimodal molecular weight distribution. Component B and/or component E may be monomodal or multimodal.

As used herein, the terms“monomodal polypropylene” or“polypropylene with a monomodal molecular weight distribution” refer to polypropylene having one maximum in their molecular weight distribution curve, which is also defined as a unimodal distribution curve. As used herein, the terms“polypropylene with a bimodal molecular weight distribution” or“bimodal polypropylene” refer to polypropylene having a distribution curve being the sum of two unimodal molecular weight distribution curves, and refer to a polypropylene product having two distinct but possibly overlapping populations of polypropylene macromolecules each having different weight average molecular weights.

As used herein, the terms“polypropylene with a multimodal molecular weight distribution” or “multimodal polypropylene” refer to polypropylene with a distribution curve that is the sum of at least two, preferably more than two unimodal distribution curves, and refer to a polypropylene product having two or more distinct but possibly overlapping populations of polypropylene macromolecules each having different weight average molecular weights. The multimodal polypropylene can have an“apparent monomodal” molecular weight distribution, which is a molecular weight distribution curve with a single peak and no shoulder. In an embodiment, said polypropylene resin having a multimodal, preferably bimodal, molecular weight distribution can be obtained by physically blending at least two polypropylene fractions.

Component B and/or component E comprises one or more polypropylenes selected from propylene homopolymers, copolymers of propylene and at least one comonomer, or mixture thereof. Suitable comonomers comprise but are not limited to ethylene and aliphatic C4-C20 alpha-olefins. Examples of suitable aliphatic C4-C20 alpha-olefins include 1 -butene, 1-pentene, 4-methyl-1-pentene, 1 -hexene, 1-octene, 1-decene, 1-dodecene, 1-tetradecene, 1- hexadecene, 1-octadecene and 1-eicosene.

In a preferred embodiment of the disclosure, the Component B and/or component E is or comprise a homopolymer of propylene. A homopolymer according to this disclosure has less than 0.2 wt.%, preferably less than 0.1 wt.%, more preferably less than 0.05 wt.% and most preferably less than 0.005 wt.%, of alpha-olefins other than propylene in the polymer. Most preferred, no other alpha-olefins are detectable. Accordingly, when the polypropylene resin is a homopolymer of propylene, the comonomer content in the polypropylene is less than 0.1 wt.%, preferably less than 0.05 wt.% and more preferably less than 0.005 wt.% based on the total weight of the polypropylene.

In an embodiment component B, and/or component E, is or comprises a random copolymer of propylene and at least one comonomer. In such a case, component B and/or component E comprises at least 0.1 wt.% of comonomer(s), preferably at least 1 wt.% based on the total weight of the random copolymer of propylene and at least one comonomer. With preference, it comprises up to 10 wt.% of comonomer(s) and most preferably up to 6 wt.%. Preferably, the random copolymers are copolymers of propylene and ethylene.

In an embodiment, component B and/or component E is or comprises a heterophasic propylene copolymer resin. The heterophasic propylene copolymers comprise a matrix propylene polymer phase and a dispersed rubber phase. Wth preference, the rubber is ethylene propylene rubber.

The content of component B in the polyolefin composition is at least 10 wt.% based on the total weight of the polyolefin composition, preferably at least 15 wt.% or at least 20 wt.%, more preferably at least 25 wt.% or at least 27 wt.% or at least 30 wt.%, even more preferably at least 40 wt.%, most preferably at least 50 wt.%, and even most preferably at least 60 wt.%, or at least 70 wt.%.

The content of component B in the polyolefin composition is at most 90 wt.% based on the total weight of the polyolefin composition, preferably at most 85 wt.% or at most 80 wt.%, more preferably at most 75 wt.% or at most 70 wt.%, even more preferably at most 67 wt.% or at most 65 wt.% or at most 60 wt.%, most preferably at most 50 wt.%, and even most preferably at most 40 wt.%, or at most 30 wt.%.

The content of component E in the polyolefin composition is at least 10 wt.% based on the total weight of the polyolefin composition, preferably at least 15 wt.% or at least 20 wt.%, more preferably at least 25 wt.% or at least 27 wt.% or at least 30 wt.%, even more preferably at least 40 wt.%, most preferably at least 50 wt.%, and even most preferably at least 60 wt.%, or at least 70 wt.%.

The content of component E in the polyolefin composition is at most 90 wt.% based on the total weight of the polyolefin composition, preferably at most 85 wt.% or at most 80 wt.%, more preferably at most 75 wt.% or at most 70 wt.%, even more preferably at most 67 wt.% or at most 65 wt.% or at most 60 wt.%, most preferably at most 50 wt.%, and even most preferably at most 40 wt.%, or at most 30 wt.%. An example of a commercially available propylene homopolymer suitable according to the disclosure is polypropylene:

- PPH 7060 (having an MI2 of 12 g/10 min as determined by ISO 1133:1997 at 230 °C/ 2.16 kg and a density of 0.905 g/cm³ according to ISO 1183 at 23°C) marketed by TOTAL®.

PPR 6288 (having an MI2 of 8 g/10 min as determined by ISO 1133: 1997 at 230 °C/ 2.16 kg and a density of 0.902 g/cm³ according to ISO 1183 at 23°C) marketed by TOTAL®.

- PPC 7712 (having an MI2 of 13 g/10 min as determined by ISO 1133:1997 at 230 °C/ 2.16 kg and a density of 0.905 g/cm³ according to ISO 1183 at 23°C) marketed by TOTAL®.

PPC 5660 (having an MI2 of 7 g/10 min as determined by ISO 1133: 1997 at 230 °C/ 2.16 kg and a density of 0.905 g/cm³ according to ISO 1183 at 23°C) marketed by TOTAL®.

MR 2002 (having an MI2 of 15 g/10 min as determined by ISO 1 133: 1997 at 230 °C/ 2.16 kg and a density of 0.905 g/cm³ according to ISO 1183 at 23°C) marketed by TOTAL®.

An example of a commercially available polypropylene post-consumer resin (PCR-PP), that can be used as component B (PCRB) in the process according to the disclosure, is PP Regranulat 500-S or PP Regranulat 530-S both marketed by Vogt Plastic GmbH.

The polypropylene post-consumer resin (PCR-PP) that can be used in accordance with the disclosure is preferably originated from a specific collection of domestic or household waste, and/or from the end of life vehicles (ELV) waste.

In a preferred embodiment, the polypropylene recycled resin (rPP) that can be used in accordance with the disclosure comprises less than 10 wt.% based on the total weight of the recycled resin of polymers other than polypropylene. For example, the polypropylene recycled resin may contain up to 10 wt.% of polyethylene based on the total weight of the polypropylene recycled resin (rPP).

The use of a polypropylene recycled resin (rPP) as component B allows the increase of the total content of the recycled resins in the polyolefin composition.

The presence of component E in the polyolefin composition is optional. Component E comprises one or more polypropylenes and may be present when component D is a recycled resin selected from a polypropylene post-consumer resin (PCR-PP), a polypropylene post industrial resin (PIR-PP), a polyolefin post-consumer resin (PCR-PO), a polyolefin post industrial resin (PIR-PO) or a mixture thereof. Selection of components A and/or B provided as polyolefin post-consumer resin

In an embodiment of the disclosure, the components A and B are provided together as a recycled polyolefin resin (rPO) selected from polyolefin post-consumer resin (PCR-PO) and/or polyolefin post-industrial resins (PIR-PO).

The polyolefin recycled resin (rPO) suitable for the disclosure comprises at least 30 wt.% of polyethylene based on the total weight of the polyolefin recycled resin and/or comprises at least 30 wt.% of polypropylene based on the total weight of the polyolefin recycled resin.

With preference, the polyolefin recycled resin (rPO) comprises at least 30 wt.% of polyethylene based on the total weight of the polyolefin recycled resin, preferably at least 40 wt.%, more preferably at least 50 wt.%, even more preferably at least 60 wt.%, and most preferably at least 70 wt.%

In an embodiment, the polyolefin recycled resin (rPO) comprises at least 30 wt.% of polypropylene based on the total weight of the polyolefin recycled resin, preferably at least 40 wt.%, more preferably at least 50 wt.%, even more preferably at least 60 wt.%, and most preferably at least 70 wt.%

Examples of polyolefin post-consumer resin (PCR-PO) are Regranulat 920-L and Regranulat 920-H both marketed by Vogt-plastic GmbH.

The total content recycled resin (RRT) in the polyolefin composition is the sum of the content of the recycled resins in the composition. The total content of the recycle resin (wt.% RRT) in the polyolefin composition is defined by the equation (1): wt.% RRT= wt.% PCR-PP + wt.% PCR-PE + wt.% PCR-PO + wt.% PIR-PP + wt.% PIR-PE + wt.% PIR-PO (1)

In an embodiment, the total content recycled resin (RRT) in the polyolefin composition is at least 40 wt.% based on the total weight of the polyolefin composition, preferably at least 42 wt.%, more preferably at least 45 wt.%, even more preferably at least 50 wt.% and most preferably at least 52 wt.%, at least 60 wt.% or at least 70 wt.%. With preference, the total content of the recycled resin (RRT) in the polyolefin composition ranges from 50 to 99 wt.% based on the total weight of the polyolefin composition.

Selection of the coupling agent (Component C) The disclosure provides the addition of a coupling agent (component C) to the polyolefin composition wherein the content of component C preferably ranges from 0.5 to 15 wt.% based on the total weight of the polyolefin composition, more preferably from 0.6 to 10.0 wt.%, even more preferably from 0.7 wt.% to 8.0 wt.%, most preferably from 0.8 wt.% to 7.0 wt.%, even most preferably from 0.9 wt.% to 6.0 wt.%, or from 1.0 wt.% to 5.0 wt.

In accordance with the disclosure, the coupling agent (component C) is one or more epoxy functionalized polymers, preferably it is or comprises one or more diepoxy functionalized polymers.

More preferably component C is one or more epoxy functionalized polymers selected from: one or more diepoxy polyethylene glycols; and/or

one or more ethylene - acrylic ester - glycidyl methacrylate terpolymers.

Suitable epoxy functionalized polymers that can be used in the disclosure are selected from Lotader AX8900 commercially available from Arkema (ethylene - acrylic ester - glycidyl methacrylate terpolymer).

In an embodiment, component C has a weight average molecular weight (Mw) of at least 10,000 g/mol, preferably at least 12,000 g/mol, more preferably at least 15,000 g/mol, even more preferably at least 20,000 g/mol, most preferably at least 30,000 g/mol, or at least 40, 000 g/mol, or at least 45,000 g/mol, or at least 50,000 g/mol, or at least 55,000 g/mol, or at least 60,000 g/mol.

In an embodiment, component C has a number average molecular weight (Mn) of at least 2.400 g/mol, more preferably at least 2,500 g/mol, even more preferably at least 3,000 g/mol, most preferably at least 5,000 g/mol, even most preferably at least 8,000 g/mil, or at least 10,000 g/mol, or at least 12,000 g/mol, or at least 13,000 g/mol, or at least 15,000 g/mol.

More preferably component C has a weight average molecular weight (Mw) of at least 10,000 g/mol and/or a number average molecular weight (Mn) of at least 2,400 g/mol.

The component C can be directly blended with the other components to form the polyolefin composition.

Selection of the acid-grafted polyolefin and/or of the anhydride-modified polyolefin

(Component H)

In an embodiment, component H is one or more grafted and/or modified polyolefins selected from acid-grafted polypropylene, acid-grafted polyethylene, anhydride-modified polypropylene, and anhydride-modified polyethylene. When the component H is or comprises comprises acid-grafted polyethylene and/or anhydride-modified polyethylene. The polyethylene is selected from ethylene homopolymers, copolymers of ethylene and at least one comonomer, or mixture thereof. Suitable comonomers comprise but are not limited to aliphatic C3-C20 alpha-olefins. Examples of suitable aliphatic C3-C20 alpha-olefins include propylene, 1 -butene, 1-pentene, 4-methyl-1-pentene, 1 -hexene, 1-octene, 1-decene, 1-dodecene, 1-tetradecene, 1-hexadecene, 1-octadecene and 1- eicosene.

In case the component H is or comprises an ethylene copolymer, it comprises at least 0.1 wt.% of comonomer, preferably at least 1 wt.% based on the total weight of the copolymer. The ethylene copolymer comprises up to 10 wt.% of comonomer based on the total weight of the copolymer, and most preferably up to 6 wt.%. In an embodiment of the disclosure, the comonomer is 1 -hexene.

When the component H is or comprises acid-grafted polypropylene and/or anhydride-modified polypropylene, the polypropylene is selected from propylene homopolymers, copolymers of propylene and at least one comonomer, or mixture thereof. Suitable comonomers comprise but are not limited to ethylene and aliphatic C4-C20 alpha-olefins. Examples of suitable aliphatic C4-C20 alpha-olefins include 1-butene, 1-pentene, 4-methyl-1-pentene, 1-hexene, 1-octene, 1- decene, 1-dodecene, 1-tetradecene, 1-hexadecene, 1-octadecene and 1-eicosene.

In case the component H is or comprises a propylene copolymer, said copolymer is a random copolymer of propylene and at least one comonomer. In such a case, the random propylene copolymer of component H comprises at least 0.1 wt.% of comonomer(s), preferably at least 1 wt.% based on the total weight of the random copolymer of propylene and at least one comonomer. With preference, it comprises up to 10 wt.% of comonomer(s) and most preferably up to 6 wt.%. Preferably, the random copolymers are copolymers of propylene and ethylene. For example, the polyolefin of component H is or comprises a polypropylene homopolymer and/or a random copolymer of propylene and at least one comonomer.

With preference, component H is one or more grafted and/or modified polyolefins selected from acrylic acid-grafted polyolefin, fumaric acid-grafted polyolefin, maleic acid-grafted polyolefin, methacrylic acid-grafted polyolefin, nadic acid-grafted polyolefin, citraconic acid- grafted polyolefin, itaconic acid-grafted polyolefin, acrylic anhydride-modified polyolefin, fumaric anhydride-modified polyolefin, maleic anhydride-modified polyolefin, methacrylic anhydride-modified polyolefin, nadic anhydride-modified polyolefin, citraconic anhydride- modified polyolefin, itaconic anhydride-modified polyolefin; wherein the polyolefin is selected from polyethylene and/or polypropylene.

In other words, component H is one or more grafted and/or modified polyolefins selected from acrylic acid-grafted polyethylene, fumaric acid-grafted polyethylene, maleic acid-grafted polyethylene, methacrylic acid-grafted polyethylene, nadic acid-grafted polyethylene, citraconic acid-grafted polyethylene, itaconic acid-grafted polyethylene, acrylic anhydride modified polyethylene, fumaric anhydride modified polyethylene, maleic anhydride-modified polyethylene, methacrylic anhydride modified polyethylene, nadic anhydride modified polyethylene, citraconic anhydride modified polyethylene, itaconic anhydride modified polyethylene, acrylic acid-grafted polypropylene, fumaric acid-grafted polypropylene, maleic acid-grafted polypropylene, methacrylic acid-grafted polypropylene, nadic acid-grafted polypropylene, citraconic acid-grafted polypropylene, itaconic acid-grafted polypropylene, acrylic anhydride modified polypropylene, fumaric anhydride modified polypropylene, maleic anhydride-modified polypropylene, methacrylic anhydride modified polypropylene, nadic anhydride modified polypropylene, citraconic anhydride modified polypropylene, itaconic anhydride-modified polypropylene.

The component H can be grafted or modified in situ or provided in the form of a commercial product already acid-grafted or anhydride-modified.

In an embodiment, component H has a weight average molecular weight (Mw) of at least 10,000 g/mol, preferably at least 12,000 g/mol, more preferably at least 15,000 g/mol, even more preferably at least 20,000 g/mol, most preferably at least 30,000 g/mol, or at least 40, 000 g/mol, or at least 45,000 g/mol, or at least 50,000 g/mol, or at least 55,000 g/mol, or at least 60,000 g/mol. In an embodiment, component H has a number average molecular weight (Mn) of at least 2.400 g/mol, more preferably at least 2,500 g/mol, even more preferably at least 3,000 g/mol, most preferably at least 5,000 g/mol, even most preferably at least 8,000 g/mil, or at least 10,000 g/mol, or at least 12,000 g/mol, or at least 13,000 g/mol, or at least 150,00 g/mol.

More preferably component H has a weight average molecular weight (Mw) of at least 10,000 g/mol and/or a number average molecular weight (Mn) of at least 2,400 g/mol.

For example, component H has an MI2 of at most 500 g/10 min according to ISO 1 133: 1997 under a load of 2.16 kg and at 190°C when the polyolefin is polyethylene or at 230°C when the polyolefin is or comprises polypropylene; preferably of at most 300 g/10 min; more preferably of at most 250 g/10min, most preferably of at most 200 g /10 min, and even most preferably at most 175 g/10 min.

The compatibilizer composition: blend of component C and component H

In accordance with the disclosure, components C and H form a compatibilizer composition that can be prepared before its addition to the polyethylene and to the polypropylene to form the polyolefin composition. Alternatively, it is prepared in situ in the extruder during the melt blending step.

In a preferred embodiment, component H is one or more maleic anhydride-modified polypropylenes and component C is one or more ethylene - acrylic ester - glycidyl methacrylate terpolymers.

In an embodiment, the total content of both component C and component H ranges from 1 to 30 wt.% based on the total weight of the polyolefin composition; preferably from 2 to 25 wt.%, more preferably from 3 to 20 wt.%, even more preferably from 4 wt.% to 15 wt.%, most preferably from 5 wt.% to 12 wt.%, or from 6 wt.% to 10 wt.%. In an embodiment, the total content of both component C and component H is more than 4 wt.% based on the total weight of the polyolefin composition, preferably more than 4.5 wt.% even more preferably more than 5 wt.%.

When the compatibilizer composition is prepared before being melt-blend to the other components, it is preferably added to the polyolefin composition in a content ranging from 1 to 30 wt.% based on the total weight of the polyolefin composition; preferably from 2 to 25 wt.%, more preferably from 3 to 20 wt.%, even more preferably from 4 wt.% to 15 wt.%, most preferably from 5 wt.% to 12 wt.%, or from 6 wt.% to 10 wt.%.

In an embodiment, the total content of the compatibilizer composition is more than 4 wt.% based on the total weight of the polyolefin composition, preferably more than 4.5 wt.% even more preferably more than 5 wt.%.

For example, the weight ratio of component C to component H in the compatibilizer composition is ranging between 5: 1 to 1 :5, preferably between 3:1 to 1 :3, more preferably between 2:1 to 1 :2 and most preferably is 1 :1.

In a preferred embodiment, component C and/or component H have a weight average molecular weight (Mw) of at least 10,000 g/mol and/or a number average molecular weight (Mn) of at least 2,400 g/mol.

Possible hydrolysis of the anhydride function of component H

The hydrolysis of the anhydride function of component H may further enhance the mechanical properties of the composition, such as the strain at break and/or the impact resistance.

Selection of the filler (component F)

In a preferred embodiment, in order to enhance the mechanical properties, the process further comprises the step of providing a component F being a filler and the step of melt-blending the components to form a polyolefin composition comprises melt-blending the component F with the other components to form the polyolefin composition.

The component F is preferably selected from talc mineral filler, wollastonite, calcium carbonate, modified calcium carbonate, coated calcium carbonate, glass fibres, bamboo fibres, flax fibres, hemp fibres, carbon black, carbon nanotubes, graphene nanotubes, and any mixture thereof; more preferably component F is selected from glass fibres and carbon nanotubes.

Examples of talc that can be used as component F of the present disclosure is talc filler Finntalc M05SL and Finntalc M15, both manufactured and sold by Mondo Minerals (CAS-No. 14807-96-6. Both are considered to be standard talc in the context of the disclosure. Finntalc M05SL has a median particle size (d50) of 2.2 pm. Finntalc M15 has a median particle size (d50) of 4.5 pm.

Examples of carbon-nanotubes commercially available that can be used in the context of the disclosure are NC7000 marketed by Nanocyl.

The content of component F ranges from 0 to 50 wt.% based on the total weight of the polyolefin composition; preferably from 0.1 to 50.0 wt.%, more preferably from 0.2 wt.% to 40.0 wt.%, even more preferably from 0.5 wt.% to 30.0 wt.%, most preferably from 1.0 wt.% to 20 wt.%, even most preferably from 1.5 wt.% to 15.0 wt.%, or from 2.5 wt.% to 12.5 wt.%, or from 5.0 wt.% to 10.0 wt.%.

In an embodiment, the polyolefin composition comprises at least 0.1 wt.% of component F, based on the total weight of the polyolefin composition, preferably at least 0.5 wt.%, more preferably at least 1.0 wt.%, even more preferably of at least 1.5 wt.%, most preferably at least

2.5 wt.% and even most preferably at least 5.0 wt.%.

With preference, the polyolefin composition comprises at most 40.0 wt.% of component F, based on the total weight of the polyolefin composition, preferably at most 30 wt.%, more preferably at most 20 wt.%, even more preferably at most 15 wt.%, most preferably at most

12.5 wt.% or at most 10.0 wt.%.

Selection of the elastomer (component G)

In a preferred embodiment, in order to enhance the impact properties, the process further comprises the step of providing a component G being one or more elastomers and the step of melt-blending the components to form a polyolefin composition comprises melt-blending the component G with the other components to form the polyolefin composition. The component G, when present, is preferably selected from copolymers of ethylene with a C3-Cio a-olefin containing at least 20 wt. %, preferably from 20 to 70 wt. %, of C3-Cio a-olefin (determined by ¹³C-NMR analysis). Suitable and preferred copolymers commercially available are obtained with metallocene or constrained geometry catalysis and typically have molecular weight distribution (Mw/Mn measured via GPC) ranging from 1 to 3.

With preference, component G is selected from elastomeric copolymers of ethylene with 1- octene, elastomeric copolymers of ethylene with 1 -butene and any mixture thereof.

For example, component G is selected from:

elastomeric copolymers of ethylene with 1-octene having from 20 wt. % to 45 wt. % of 1- octene (determined by ¹³C-NMR analysis); and/or

elastomeric thermoplastic copolymers of ethylene with 1 -butene having from 20 wt. % to 40 wt. % of 1-butene (determined by ¹³C-NMR analysis); and/or

elastomeric thermoplastic copolymers of ethylene with propylene.

Non-exhaustive specific examples of elastomer that can be used in the process according to the disclosure are:

a) an ethylene-butene-1 random copolymer rubber such as:

ENGAGE 7642 produced by The Dow Chemical Co. Ltd., having an MI2 of 0.5 g/10 min. ENGAGE 7447 produced by The Dow Chemical Co. Ltd., having an MI2 of 5.0 g/10 min.

ENGAGE 7467 produced by The Dow Chemical Co. Ltd., having an MI2 of 1.2 g/10 min.

Tafmer A0550S from Mitsui having an MI2 of 0.5 g/10 min.

Tafmer A1550S from Mitsui having an MI2 of 1.0 g/10 min.

Lucene 168 from LG having an MI2 of 1.2 g/10 min. b) an ethylene-octene-1 random copolymer rubber such as:

- Affinity EG8100 from The Dow Chemical Co. Ltd., having an MI2 of 1.0 g/10 min.

- Affinity EG8150 from The Dow Chemical Co. Ltd., having an MI2 of 0.5 g/10 min. c) an ethylene-propylene copolymer rubber such as:

- Exxon IT0316 from ExxonMobil, having an ethylene content of 16 wt.%.

For the cited elastomers, the MI2 was determined according to ISO 1133:1997 (190 °C /2.16 Kg).

In an embodiment, alternative or cumulative, the composition further comprises from 0.1 to 15 wt.%, based on the total weight of the polyolefin composition of one or more styrene-based thermoplastic elastomers (TPE-S) selected from SIS (Styrene isoprene styrene block copolymers), SEPS (Hydrogenated styrene isoprene styrene block copolymers), SBS (Styrene butadiene styrene block copolymers), SEBS (Hydrogenated styrenic butadiene copolymers), SBSS (Styrene butadiene styrene styrene block copolymers), and any mixture thereof.

Preferably, the polyolefin composition comprises at least 0.1 wt.% of component G, based on the total weight of the polyolefin composition, preferably at least 0.5 wt.%, more preferably at least 1.0 wt.%, even more preferably of at least 1.5 wt.%, most preferably at least 2.5 wt.% and even most preferably at least 5.0 wt.%.

With preference, the polyolefin composition comprises at most 9.8 wt.% of component G, based on the total weight of the polyolefin composition, preferably at most 9.5 wt.%, more preferably at most 9.3 wt.%, even more preferably at most 9.1 wt.%, most preferably at most 9.0 wt.%, and even most preferably at most 8.5 wt.%.

In a preferred embodiment, the content of component G ranges from 0 to 10 wt.% based on the total weight of the polyolefin composition; preferably from 0.1 to 10.0 wt.%, more preferably from 0.2 wt.% to 9.8 wt.%, even more preferably from 0.5 wt.% to 9.5 wt.%, most preferably from 1.0 wt.% to 9.3 wt.%, even most preferably from 1.5 wt.% to 9.1 wt.%, or from 2.5 wt.% to 9.0 wt.%, or from 5.0 wt.% to 8.5 wt.%.

Component G has an MI2 ranging from 0.5 to 5.0 g/10 min as determined according to ISO 1 133: 1997 conditions D, at a temperature of 190 °C and under a load of 2.16 kg.

With preference, component G has an MI2 of at most 4.5 g/10 min as determined according to ISO 1133: 1997 conditions D, at a temperature of 190 °C and under a load of 2.16 kg, preferably of at most 4.0 g/10 min, more preferably of at most 3.5 g/10 min, even more preferably of at most 3.0 g/10 min, most preferably of at most 2.5 g/10 min and even most preferably of at most 2.0 g/10 min.

TEST METHODS

The melt index (MI2) of polypropylene and polypropylene compositions is determined according to the method of standard ISO 1133: 1997, conditions M, at a temperature of 230 °C and under a load of 2.16 kg using a die of 2.096 mm.

The melt index (MI2) of polyethylene and polyethylene compositions is determined according to the method of standard ISO 1 133: 1997, conditions D, at a temperature of 190 °C and under a load of 2.16 kg using a die of 2.096 mm. The density of polyethylene and polyethylene compositions is measured according to the method of standard ISO 1 183 at a temperature of 23 °C.

The molecular weight Mn (number average molecular weight), Mw (weight average molecular weight), Mz (z average molecular weight) and molecular weight distribution D (Mw/Mn) and D’ (Mz/Mw) are determined by size exclusion chromatography (SEC) and in particular by gel permeation chromatography (GPC). Briefly, a GPC-IR5 from Polymer Char was used: 10 mg polypropylene sample is dissolved at 160 °C in 10 mL of trichlorobenzene (technical grade) for 1 hour. Analytical conditions for the GPC-IR from Polymer Char are:

Injection volume: +/- 0.4 mL;

- Automatic sample preparation and injector temperature: 160 °C;

Column temperature: 145 °C;

Detector temperature: 160 °C;

Column set: 2 Shodex AT-806MS and 1 Styragel HT6E;

Flow rate: 1 mL/min;

- Detector: IR5 Infrared detector (2800-3000 cm^-1);

Calibration: Narrow standards of polystyrene (commercially available);

Calculation for polypropylene: Based on Mark-Houwink relation (logio(M_PP) = logio(M_PS) - 0,25323); cut off on the low molecular weight end at M_PP = 1000;

Calculation for polyethylene: Based on Mark-Houwink relation (logio(M_PE) = 0.965909x logio(Mps) - 0,28264); cut off on the low molecular weight end at M_PE = 1000.

The molecular weight averages used in establishing molecular weight/property relationships are the number average (M_n), weight average (M_w) and z average (M_z) molecular weight. These averages are defined by the following expressions and are determined from the calculated M,:

Here N, and W, are the number and weight, respectively, of molecules having molecular weight Mi. The third representation in each case (farthest right) defines how one obtains these averages from SEC chromatograms h, is the height (from baseline) of the SEC curve at the i_th elution fraction and M, is the molecular weight of species eluting at this increment.

The molecular weight distribution (MWD) is then calculated as Mw/Mn.

The comonomer content of polypropylene is determined by ¹³C-NMR analysis of pellets according to the method described by G.J. Ray et al. in Macromolecules, vol. 10, n° 4, 1977, p. 773-778.

The ¹³C-NMR analysis is performed using a 400 MHz or 500 MHz Bruker NMR spectrometer under conditions such that the signal intensity in the spectrum is directly proportional to the total number of contributing carbon atoms in the sample. Such conditions are well known to the person skilled in the art and include for example sufficient relaxation time, etc. In practice, the intensity of a signal is obtained from its integral, i.e. the corresponding area. The data is acquired using proton decoupling, 2000 to 4000 scans per spectrum with 10 mm at room temperature through or 240 scans per spectrum with a 10 mm cryoprobe, a pulse repetition delay of 11 seconds and a spectral width of 25000 Hz (+/- 3000 Hz). The sample is prepared by dissolving a sufficient amount of polymer in 1 ,2,4-trichlorobenzene (TCB, 99%, spectroscopic grade) at 130 °C and occasional agitation to homogenise the sample, followed by the addition of hexadeuterobenzene (Obϋ_d, spectroscopic grade) and a minor amount of hexamethyldisiloxane (HMDS, 99.5+ %), with HMDS serving as internal standard. To give an example, about 200 mg to 600 mg of polymer is dissolved in 2.0 ml_ of TCB, followed by addition of 0.5 ml_ of Obϋb and 2 to 3 drops of HMDS.

Following data acquisition, the chemical shifts are referenced to the signal of the internal standard HMDS, which is assigned a value of 2.03 ppm.

The Charpy impact strength (notched) at 23 °C was determined according to ISO 179.

The Izod impact strength (notched) at 23 °C and at -20 °C was determined according to ISO 180.

The mechanical properties such as the tensile modulus, the strength at break, the strength at yield, the elongation at yield and elongation at break were determined according to ISO 527 1 B/1 A. The properties were tested at 23 °C.

Elastic modulus is obtained during tensile strength test. It is the slope of the line between 0.05 and 0.25 % deformation.

The following non-limiting examples illustrate the disclosure. EXAMPLES

Example 1 : reference materials (virgin polymers) and production of PP/PE blends from said reference materials Sample 1 : polypropylene PP1 was PPH7060 commercially available from TOTAL ®.

Sample 2: polyethylene PE1 was PE5502 commercially available from TOTAL ®.

Sample 3: A PP/PE blend was produced as a reference sample. The polypropylene PP1 was PPH7060 and the polyethylene PE1 was PE5502. The blend was produced by extrusion at 200°C for 10 minutes at 100 rpm under a nitrogen blanket. Collected material (after 10 minutes in the Brabender) was injected at 230 °C. The pressure held to 1 bar for 40 seconds and then no pressure was applied for 20 seconds. Mechanical properties were measured on injected items. Specification of the virgin resins used and the results of the mechanical tests are provided in Table 1.

Table 1 : reference materials

Functionalized polypropylene, functionalized polyethylene and/or coupling agent were added separately to the reference blend described as sample 3 to produce samples 4 to 6.

Sample 4: 20 g of polypropylene PP1 (PPH7060), 20 g of polyethylene PE1 (PE5802) and 2.2 g of ethylene - acrylic ester - glycidyl methacrylate terpolymer (Lotader AX8900) were dry blended and added in one stage during 60 sec. at 200°C for 10 minutes at 100 rpm under a nitrogen blanket. Collected material after 10 minutes in Brabender was injected at 230 °C/hold pressure 1 bar during 40 sec + 20 sec without pressure.

Sample 5: 20 g of polypropylene PP1 (PPH7060), 20 g of polyethylene PE1 (PE5802) and 2.2g of maleic anhydride functionalized polypropylene copolymer (EXXELOR1015) were dry blended and added in one stage during 60 sec. at 200°C for 10 minutes at 100 rpm under a nitrogen blanket. Collected material after 10 minutes in Brabender was injected at 230°C/hold pressure 1 bar during 40 sec + 20 sec without pressure.

Sample 6: A compatibilizer composition (comp 1) was prepared by dry blending 21 g of a maleic anhydride functionalized polypropylene copolymer (EXXELOR1015) and 21 of ethylene - acrylic ester - glycidyl methacrylate terpolymer (Lotader AX8900) and kneaded in Brabender at 200°C for 10 minutes at 100 rpm under a nitrogen blanket.

2 g of the compatibilizer composition 1 were added to 19 g of polypropylene PP1 (PPH7060) and 19 g of polyethylene PE1 (PE5802) in one stage at 200°C for 10 minutes at 100 rpm under a nitrogen blanket. Collected material after 10 minutes in Brabender was injected at 230°C/hold pressure 1 bar during 40 sec + 20 sec without pressure.

The results of the mechanical tests are provided in Table 2

Table 2: properties of the blends

From the results, it can be seen that when added separately the ethylene - acrylic ester - glycidyl methacrylate terpolymer (Lotader AX8900) and the maleic anhydride functionalized polypropylene copolymer (EXXELOR1015) showed no or little improvement of the mechanical properties of the PE/PP blend. However, a significant improvement of said mechanical properties is shown when both the ethylene - acrylic ester - glycidyl methacrylate terpolymer (Lotader AX8900) and the maleic anhydride functionalized polypropylene copolymer (EXXELOR1015) are added together to the PE/PP blend demonstrating synergy between the two components.

Example 2: influence of the content of the compatibilizer composition in the PE/PP blend Further tests have been conducted according to the same processing conditions than in Example 1 except that the content of compatibilizer composition (comp 1) was changed to determine the optimal content. The results are reported in the below Table 3, sample 3 and 6 have been incorporated to ease the comparison.

Table 3: Properties of the blends

From the results, it can be seen that it is preferable to keep the compatibilizer composition content below 30 wt.% based on the total weight of the composition. The best results have been obtained with a content of compatibilizer composition that is superior to 2 wt.% and equal to or less than 15 wt.%, preferably equal to or less than 10 wt.%. Indeed, a decrease in tensile modulus was observed with a content of compatibilizer composition above 30 wt.%.

Example 3: influence of the components of the compatibilizer composition

Further tests have been conducted according to the same processing conditions than in Example 1 , except that the compatibilizer composition was changed. The results are provided in the below Table 4, sample 3 and 8 have been incorporated to ease the comparison. Compatibilizer composition 1 (comp 1): blend 50:50 wt.% of maleic anhydride functionalized polypropylene copolymer (EXXELOR PO1015 commercially available from ExxonMobil) and an ethylene - acrylic ester - glycidyl methacrylate terpolymer (Lotader AX8900 commercially available from Arkema). EXXELOR PO1015 has an MI2 of 150 g/10 min as determined according to ISO 1133:1997 conditions M, at a temperature of 230°C and under a load of 2.16 kg.

Compatibilizer composition 2 (comp 2): blend of 45 wt.% of a maleic anhydride polypropylene wax (Licocene PP MA 6452 commercially available from Clariant), 45 wt.% of a maleic anhydride polyethylene wax (Licocene PE MA 4351 commercially available from Clariant) and 10 wt.% of an ethylene - acrylic ester - glycidyl methacrylate terpolymer (Lotader AX8900 commercially available from Arkema).

Compatibilizer composition 3 (comp 3): blend 50:50 wt.% of an ethylene - acrylic ester - glycidyl methacrylate terpolymer (Lotader AX8900 commercially available from Arkema) and a maleic anhydride-modified polypropylene (OREVAC 18722 commercially available from Arkema). OREVAC 18722 has an MI2 of 7 g/10 min as determined according to ISO 1133:1997 conditions M, at a temperature of 230°C and under a load of 2.16 kg.

The different compatibilizer compositions have been added in the polyolefin composition at a content of 10 wt.% based on the total weight of the polyolefin composition. The results are reported in the below Table 4, sample 3 and 8 have been incorporated to ease the comparison.

Table 4: Properties of the blends

From the results, it can be seen that Compatibilizer composition 1 (comp 1) is providing the best mechanical improvement. It is believed that composition 2 provides bad results because of the low Mw of the Licocene waxes. While the improvement in notched izod is the same for both samples comprising comp 1 and comp 3, the elongation at break shows a better increase in sample 8 comprising comp 1 by comparison to sample 11 comprising comp 3, and therefore a better balance of properties. Example 4: influence of the preliminary preparation of the compatibilizer composition

A further test has been conducted according to the same processing conditions than in Example 1 except that the components of the compatibilizer composition were not pre-blended before the step of melt-blending the components to form a polyolefin composition. This test was made in order to determine the need for compatibilizer composition production before mixing it with the polyolefins. The results are provided in the below Table 5, results for sample 3 and 8 have been incorporated to ease the comparison.

Table 5: Properties of the blends

From the results, it can be seen that the properties are almost similar, but the impact properties are better. From the SEM results, it can be seen that dispersion seems more finely dispersed when the compatibilizer composition is produced in-situ. There is no need to prepare the compatibilizer composition before the step of melt-blending the components to form a polyolefin composition. Example 5: production of PP/PE blends with recycled resins

Further tests were conducted according to the same processing conditions than in example 1 except that the recycled polyethylene and the recycled polypropylene were provided separately: a polyethylene post-consumer resin (PCR-PE) and a polypropylene post consumer resin (PCR-PP). The recycled resins were blended with Comp 1 or Comp 2 as a compatibilizer composition. The results are provided in table 7 The polypropylene post-consumer resin (PCR-PP) was rPP-GP306 commercially available from Gallo Plastics.

The polyethylene post-consumer resin (PCR-PE) was EXPE807-B-0100 having the following properties: Table 6: properties of EXPE807-B-0100

Table 7: Properties of the blend

An improvement of the mechanical properties is achieved with the use of a composition comprising the compatibilizer composition comp 1. The properties are almost the same between samples 16 and 17, but slightly better when the mixture is prepared in-situ.

Claims

1. A process to produce a polyolefin composition comprising a blend of polyethylene and polypropylene characterized in that it comprises the steps of:

providing a component A, wherein component A is one or more polyethylenes; providing a component B, wherein component B is one or more polypropylenes; providing a component C, wherein component C is one or more epoxy functionalized polymers;

providing a component H, wherein component H is one or more grafted and/or modified polyolefins selected from acid-grafted polyolefins and/or anhydride- modified polyolefins; wherein the polyolefin is selected from polyethylene and/or polypropylene; wherein component H has an MI2 of at least 50 g/10 min as determined according to ISO 1133:1997 under a load of 2.16 kg and at 190°C when the polyolefin is polyethylene or at 230°C when the polyolefin is or comprises polypropylene and;

melt-blending the said components to form a polyolefin composition.

2. The process according to claim 1 , characterized in that component C is selected from:

one or more diepoxy polyethylene glycols; and/or

one or more ethylene - acrylic ester - glycidyl methacrylate terpolymers.

3. The process according to claim 1 or 2, characterized in that:

component H is one or more maleic anhydride-modified polyolefins selected from one or more maleic anhydride-modified polyethylenes and/or one or more maleic anhydride-modified polypropylenes; and/or

component H is one or more maleic anhydride-modified polypropylenes; and component C is one or more ethylene - acrylic ester - glycidyl methacrylate terpolymers.

4. The process according to any one of claims 1 to 3, characterized in that:

- the content of component C ranges from 0.5 to 15 wt.% based on the total weight of the polyolefin composition; and/or

- the content of component H ranges from 0.5 to 15 wt.% based on the total weight of the polyolefin composition; and/or

- the total content of both component C and component H ranges from 1 to 30 wt.% based on the total weight of the polyolefin composition; with preference from 5 to 10 wt.%; and/or the weight ratio of component C to component H is ranging between 2:1 to 1 :2.

5. The process according to any one of claims 1 to 4, characterized in that either or both components C and component H have a weight average molecular weight (Mw) of at least 10,000 g/mol and/or a number average molecular weight (Mn) of at least 2,400 g/mol.

6. The process according to any one of claims 1 to 5, characterized in that:

the content of component A ranges from 10 to 90 wt.% based on the total weight of the polyolefin composition, with preference from 25 to 75 wt.%; and/or component A has an MI2 ranging from 0.10 to 70.0 g/10 min as determined according to ISO 1133:1997 conditions D, at a temperature of 190°C and under a load of 2.16 kg.

7. The process according to any one of claims 1 to 6, characterized in that:

the content of component B ranges from 10 to 90 wt.% based on the total weight of the polyolefin composition, with preference from 25 to 75 wt.%; and/or component B has an MI2 ranging from 1.0 to 200.0 g/10 min as determined according to ISO 1133:1997 conditions M, at a temperature of 230°C and under a load of 2.16 kg; and/or

the component A and the component B are in a weight ratio ranging between 2:1 to 1 :2.

8. The process according to any one of claims 1 to 7, characterized in that the component A and/or the component B are recycled resins selected from post-consumer resins (PCR) and/or post-industrial resins (PIR); with preference:

the components A and B are provided separately as a polyethylene recycled resin (rPE), and a polypropylene recycled resin (rPP); and/or

the total content of the recycled resins (RR_T) in the polyolefin composition ranges from 50 to 99 wt.% based on the total weight of the polyolefin composition.

9. The process according to claim 8, characterized in that both components A and B are recycled resins, and in that, before the step of melt blending of the components to form a polyolefin composition, the process further comprises one or more steps selected from:

providing a component D being at least one virgin polyethylene, with preference component D has an MI2 ranging from 0.10 to 70.0 g/10 min as determined according to ISO 1133:1997 conditions D, at a temperature of 190°C and under a load of 2.16 kg; and/or

providing a component E being at least one virgin polypropylene, with preference component E has an MI2 ranging from 1.0 to 200.0 g/10 min as determined according to ISO 1133:1997 conditions M, at a temperature of 230°C and under a load of 2.16 kg.

10. The process according to any one of claims 1 to 9, characterized in that component H is or comprises anhydride-modified polyolefin; wherein the polyolefin is selected from polyethylene and/or polypropylene, and in that the process further comprises a step of providing water, wherein water is provided before the step of melt blending of the components to form a polyolefin composition.

11. The process according to any one of claims from 1 to 10 characterized in that, before the step of melt blending the components to form a polyolefin composition, the process further comprises a step of providing a component F being one or more fillers; and/or the process further comprises a step of providing a component G being one or more elastomers.

12. The process according to any one of claims from 1 to 11 characterized in that the polyolefin of component H is or comprises of one or more selected from a polypropylene homopolymer, a random copolymer of propylene and at least one comonomer, a polyethylene homopolymer and a random copolymer of ethylene and at least one comonomer; and/or in that component H has an MI2 of at least 100 g/10 min as determined according to ISO 1133:1997 under a load of 2.16 kg and at 190°C when the polyolefin is polyethylene or at 230°C when the polyolefin is or comprises polypropylene and/or of at most 300 g/10 min.

13. Polyolefin composition, characterized in that it comprises

a component A being of one or more polyethylenes,

a component B being one or more polypropylenes, and

a component C being one or more epoxy functionalized polymers;

a component H being is one or more grafted and/or modified polyolefins selected from acid-grafted polyolefins and/or anhydride-modified polyolefins; wherein the polyolefin is selected from polyethylene and/or polypropylene; and wherein component H has an MI2 of at least 50 g/10 min as determined according to ISO 1133:1997 under a load of 2.16 kg and at 190°C when the polyolefin is polyethylene or at 230°C when the polyolefin is or comprises polypropylene; with preference, the polyolefin composition is produced by a process according to any one of claims 1 to 12.

14. Compatibilizer composition for use in a process according to any one of claims 1 to 12; the compatibilizer composition comprising:

a component H being one or more grafted and/or modified polyolefins selected from acid-grafted polyolefins and/or anhydride-modified polyolefins; wherein the polyolefin is selected from polyethylene and/or polypropylene; wherein component H has an MI2 of at least 50 g/10 min as determined according to ISO 1133: 1997 under a load of 2.16 kg and at 190°C when the polyolefin is polyethylene or at 230°C when the polyolefin is or comprises polypropylene, and

15. Compatibilizer composition according to claim 14, characterized in that component C is selected from:

one or more diepoxy polyethylene glycols; and/or

one or more ethylene - acrylic ester - glycidyl methacrylate terpolymers.

16. Use of the polyolefin composition obtained by the process according to any one of claims 1 to 12, or of the polyolefin composition of claim 13, to make an article in a process selected from 3D-printing, extrusion, blow-moulding, injection, injection blow moulding, injection stretch blow moulding, rotomoulding, extrusion and thermoforming.

17. Article made from the polyolefin composition obtained by the process according to any one of claims 1 to 12, or by the polyolefin composition of claim 13, preferably:

18. Use of a compatibilizer composition according to claim 14 or 15 in a polyolefin composition comprising a component A being one or more polyethylenes, a component B being one or more polypropylenes; with preference the use comprises the addition of the compatibilizer composition in a content ranging from 1 to 30 wt.% based on the total weight of the polyolefin composition.