US 11,746,219 B2
Blends of recycled resins with metallocene-catalyzed polyolefins
Robert M. Canright, Huffman, TX (US); James A. Stern, Spring, TX (US); and Kelsey L. Terrill, Houston, TX (US)
Assigned to ExxonMobil Chemical Patents Inc., Baytown, TX (US)
Filed by ExxonMobil Chemical Patents Inc., Baytown, TX (US)
Filed on May 4, 2022, as Appl. No. 17/661,958.
Claims priority of provisional application 63/362,580, filed on Apr. 6, 2022.
Prior Publication US 2022/0259417 A1, Aug. 18, 2022
Int. Cl. C08L 23/06 (2006.01)
CPC C08L 23/06 (2013.01) [C08L 2205/025 (2013.01); C08L 2205/03 (2013.01); C08L 2207/066 (2013.01); C08L 2207/20 (2013.01)] 10 Claims
OG exemplary drawing
 
1. A recycled resin composition, comprising:
at least one recycled resin;
up to about 45 wt %, based on the total weight of the composition, of a virgin HDPE containing at least 99 wt % of ethylene derived units and having a density of about 0.945 g/cm3 to about 0.970 g/cm3 and a MI2 of about 0.1 to about 1.5 g/10 min, as measured by ASTM D1238 (190° C., 2.16 kg load); and
greater than 0 wt % and up to about 10 wt %, based on the total weight of the composition, of at least one metallocene catalyzed linear low density polyethylene (mLLDPE) modifier, wherein the mLLDPE modifier comprises one or more of the following:
(i) a first mLLDPE of 80 wt % to 98 wt % ethylene and 2 wt % to 20 wt % of one or more C3-C12 alpha olefins and having a density of about 0.900 g/cm3 to about 0.945 g/cm3, molecular weight distribution (MWD, defined as Mw/Mn) of about 3.0 to 4.5, CDBI of 60% to 99%, and one or more of the following properties:
a. a melt index ratio (MIR) within the range from 25 to 40, wherein MIR is the ratio of high load melt index (HLMI, ASTM D1238 at 190° C., 21.6 kg) to melt index (MI, ASTM D1238 at 190° C., 2.16 kg);
b. an inflection point in a Van Gurp Palmen plot of phase angle vs. complex modulus (Pa) of the polyethylene copolymer; and
c. a shear thinning ratio less than 15;
(ii) a second mLLDPE of 80-98 wt % ethylene and 2-20 wt % of one or more C3-C12 alpha olefins and having a density of about 0.900 g/cm3 to about 0.940 g/cm3, MWD of 2 to 4.5, CDBI of 15% to 40%, and a broad orthogonal composition distribution; and
(iii) a third mLLDPE of 80-98 wt % ethylene and 2-20 wt % of one or more C3-C12 alpha olefins and having a density of about 0.900 g/cm3 to about 0.940 g/cm3, MWD of 6 to 10, CDBI of 15 to 40%, and a broad orthogonal composition distribution;
further wherein the recycled resin composition has one or more of the following properties: a flex modulus @ 0.05 in/min of 110,000 psi to 180,000 psi, as measured by ASTM D790, Proc. A 1% Secant Modulus and an ESCR, as measured by 100% Igepal Cond B, ASTM D1693, of about 10 hr to about 75 hr.