Process for recycling polyolefin blend composition using an ethylene copolymer compatibilizing agent

Abstract

A process is provided for preparing polymer composites from compositions comprising i) a polyolefin, ii) a polymer selected from the group consisting of polymers having hydroxyl groups and polymers having amino groups and iii) a polar ethylene copolymer having copolymerized units selected from the group consisting of C 4 -C 8 unsaturated anhydrides, monoesters of C 4 -C 8 unsaturated acids having at least two carboxylic acid groups, diesters of C 4 -C 8 unsaturated acids having at least two carboxylic acid groups and mixtures thereof. The process is suitable for use with recycle streams that contain polymeric materials that are laminates or composites of dissimilar polymers.

1 . A process for preparing a polymer composite comprising the steps of
 A. forming a composition by combining
 1. a polymer blend comprising
 a. a first polymer selected from the group consisting of polyethylenes and copolymers of ethylene and a C 3 -C 10  alpha-olefin; and 
 b. a second polymer selected from the group consisting of polyamides, polyamide resins, and mixtures of two or more thereof; 
 wherein said polymer blend has a moisture content greater than 250 ppm water, based on the total weight of said first and second polymers; and 
 
 2. a third polymer that is a polar copolymer produced by a high pressure random copolymerization process, said polar copolymer comprising copolymerized units of ethylene and from about 3 wt. % to about 25 wt. %, based on the weight of the polar copolymer, of a comonomer selected from the group consisting of C 4 -C 8  unsaturated anhydrides, monoesters of C 4 -C 8  unsaturated acids having at least two carboxylic acid groups, diesters of C 4 -C 8  unsaturated acids having at least two carboxylic acid groups and mixtures thereof; and 
 wherein said composition comprises, based on the total weight of said first, second and third polymers, 55-89 wt. % of said first polymer, 2-45 wt. % of said second polymer and 0.1-10 wt. % of said third polymer; 
   B. subjecting said composition to high shear mixing to form a polymer composite that is a homogeneous blend; and   C. recovering said polymer composite.   
   
   
       2 . A process of  claim 1  wherein said first polymer is a polyethylene. 
   
   
       3 . A process of  claim 1  wherein said first polymer is a copolymer of ethylene and a C 3 -C 10  alpha-olefin. 
   
   
       4 . A process of  claim 1  wherein said polar copolymer comprises copolymerized units of ethylene and a C 4 -C 8  unsaturated anhydride. 
   
   
       5 . A process of  claim 1  wherein said polar copolymer comprises copolymerized units of ethylene and a monoester of a C 4 -C 8  unsaturated acid having at least two carboxylic acid groups. 
   
   
       6 . A process of  claim 4  wherein said unsaturated anhydride is maleic anhydride. 
   
   
       7 . A process of  claim 5  wherein said monoester is ethyl hydrogen maleate. 
   
   
       8 . A process of  claim 1  wherein said polymer blend has a moisture content of greater than 300 ppm water, based on the total weight of said first and second polymers. 
   
   
       9 . An easily processable composition prepared by combining:
 A. a polymer blend comprising
 1. a first polymer selected from the group consisting of polyethylenes and copolymers of ethylene and a C 3 -C 10  alpha-olefin; and 
 2. a second polymer selected from the group consisting of polyamides, polyamide resins, and mixtures of two or more thereof; 
 wherein said polymer blend has a moisture content greater than 250 ppm water, based on the total weight of said first and second polymers; and 
   B. a third polymer that is a polar copolymer produced by a high pressure random copolymerization process, said polar copolymer comprising copolymerized units of ethylene and from about 3 wt. % to about 25 wt. %, based on the weight of the polar copolymer, of a comonomer selected from the group consisting of C 4 -C 8  unsaturated anhydrides, monoesters of C 4 -C 8  unsaturated acids having at least two carboxylic acid groups, diesters of C 4 -C 8  unsaturated acids having at least two carboxylic acid groups and mixtures thereof;   
     wherein said processable composition comprises, based on the total weight of said first, second and third polymers, 55-98 wt. % of said first polymer, 2-45 wt. % of said second polymer and 0.1-10 wt. % of said third polymer. 
   
   
       10 . A composition of  claim 9  wherein said first polymer is a polyethylene. 
   
   
       11 . A composition of  claim 9  wherein said first polymer is a copolymer of ethylene and a C 3 -C 10  alpha-olefin. 
   
   
       12 . A composition of  claim 9  wherein said polar copolymer comprises copolymerized units of ethylene and a C 4 -C 8  unsaturated anhydride. 
   
   
       13 . A composition of  claim 9  wherein said polar copolymer comprises copolymerized units of ethylene and a monoester of a C 4 -C 8  unsaturated acid having at least two carboxylic acid groups. 
   
   
       14 . A composition of  claim 12  wherein said unsaturated anhydride is maleic anhydride. 
   
   
       15 . A composition of  claim 13  wherein said monoester is ethyl hydrogen maleate. 
   
   
       16 . A composition of  claim 9  wherein said polymer blend has a moisture content of greater than 300 ppm water, based on the total weight of said first and second polymers. 
   
   
       17 . A process for preparing a shaped article from a composite material which comprises the steps of
 A. preparing a composite material by a process comprising the steps of
 1. forming a composition by combining
 a. a polymer blend comprising
 (1) a first polymer selected from the group consisting of polyethylenes and copolymers of ethylene and a C 3 -C 10  alpha-olefin; and 
 (2) a second polymer selected from the group consisting of polyamides, polyamide resins, and mixtures of two or more thereof; 
 wherein said polymer blend has a moisture content greater than 250 ppm water, based on the total weight of said first and second polymers; and 
 
 b. a third polymer that is a polar copolymer produced by a high pressure random copolymerization process, said polar copolymer comprising copolymerized units of ethylene and from about 3 wt. % to about 25 wt. %, based on the weight of the polar copolymer, of a comonomer selected from the group consisting of C 4 -C 8  unsaturated anhydrides, monoesters of C 4 -C 8  unsaturated acids having at least two carboxylic acid groups, diesters of C 4 -C 8  unsaturated acids having at least two carboxylic acid groups and mixtures thereof; 
 wherein said composition comprises, based on the total weight of said first, second and third polymers, 55-98 wt. % of said first polymer, 2-45 wt. % of said second polymer and 0.1-10 wt. % of said third polymer; and 
 
 2. subjecting said composition to high shear mixing to form a homogeneous composite material; and 
   B. forming said composite material into a shaped article.   
   
   
       18 . A process of  claim 17  wherein said first polymer is a polyethylene. 
   
   
       19 . A process of  claim 17  wherein said first polymer is a copolymer of ethylene and a C 3 -C 10  alpha-olefin. 
   
   
       20 . A process of  claim 17  wherein said polar copolymer comprises copolymerized units of ethylene and a C 4 -C 8  unsaturated anhydride. 
   
   
       21 . A process of  claim 17  wherein said polar copolymer comprises copolymerized units of ethylene and a monoester of a C 4 -C 8  unsaturated acid having at least two carboxylic acid groups. 
   
   
       22 . A process of  claim 20  wherein said unsaturated anhydride is maleic anhydride. 
   
   
       23 . A process of  claim 21  wherein said monoester is ethyl hydrogen maleate. 
   
   
       24 . A process of  claim 17  wherein the moisture content of said polymer blend is greater than 300 ppm water, based on the total weight of said first and second polymers. 
   
   
       25 . A shaped article prepared by the process of  claim 17 . 
   
   
       26 . A process of  claim 1  wherein said composition additionally comprises a lubricant.