WO2024078911A1 - Article comprising recycled and renewable polyethylene - Google Patents
Article comprising recycled and renewable polyethylene Download PDFInfo
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- WO2024078911A1 WO2024078911A1 PCT/EP2023/077253 EP2023077253W WO2024078911A1 WO 2024078911 A1 WO2024078911 A1 WO 2024078911A1 EP 2023077253 W EP2023077253 W EP 2023077253W WO 2024078911 A1 WO2024078911 A1 WO 2024078911A1
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- WO
- WIPO (PCT)
- Prior art keywords
- layer
- article
- polyethylene
- density
- polyethylene composition
- Prior art date
Links
- 229920001659 Renewable Polyethylene Polymers 0.000 title description 3
- -1 polyethylene Polymers 0.000 claims abstract description 86
- 239000004698 Polyethylene Substances 0.000 claims abstract description 82
- 229920000573 polyethylene Polymers 0.000 claims abstract description 82
- 239000000203 mixture Substances 0.000 claims abstract description 50
- 239000000463 material Substances 0.000 claims abstract description 35
- 239000007788 liquid Substances 0.000 claims abstract description 6
- 239000011344 liquid material Substances 0.000 claims abstract description 5
- 238000001125 extrusion Methods 0.000 claims description 20
- 239000000155 melt Substances 0.000 claims description 18
- 238000000034 method Methods 0.000 claims description 16
- 238000004064 recycling Methods 0.000 claims description 14
- 239000004088 foaming agent Substances 0.000 claims description 7
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 claims description 6
- 239000006260 foam Substances 0.000 claims description 5
- 239000004743 Polypropylene Substances 0.000 claims description 4
- 238000004519 manufacturing process Methods 0.000 claims description 4
- 229920001155 polypropylene Polymers 0.000 claims description 4
- 239000000126 substance Substances 0.000 claims description 4
- 238000010101 extrusion blow moulding Methods 0.000 claims description 3
- 239000007789 gas Substances 0.000 claims description 3
- 229910052757 nitrogen Inorganic materials 0.000 claims description 3
- 239000004215 Carbon black (E152) Substances 0.000 claims description 2
- 230000015572 biosynthetic process Effects 0.000 claims description 2
- 238000001816 cooling Methods 0.000 claims description 2
- 229930195733 hydrocarbon Natural products 0.000 claims description 2
- 150000002430 hydrocarbons Chemical class 0.000 claims description 2
- 238000003786 synthesis reaction Methods 0.000 claims description 2
- 239000000454 talc Substances 0.000 claims description 2
- 229910052623 talc Inorganic materials 0.000 claims description 2
- VXNZUUAINFGPBY-UHFFFAOYSA-N 1-Butene Chemical compound CCC=C VXNZUUAINFGPBY-UHFFFAOYSA-N 0.000 description 20
- LIKMAJRDDDTEIG-UHFFFAOYSA-N 1-hexene Chemical compound CCCCC=C LIKMAJRDDDTEIG-UHFFFAOYSA-N 0.000 description 20
- KWKAKUADMBZCLK-UHFFFAOYSA-N 1-octene Chemical compound CCCCCCC=C KWKAKUADMBZCLK-UHFFFAOYSA-N 0.000 description 20
- WSSSPWUEQFSQQG-UHFFFAOYSA-N 4-methyl-1-pentene Chemical compound CC(C)CC=C WSSSPWUEQFSQQG-UHFFFAOYSA-N 0.000 description 20
- VGGSQFUCUMXWEO-UHFFFAOYSA-N Ethene Chemical compound C=C VGGSQFUCUMXWEO-UHFFFAOYSA-N 0.000 description 14
- 239000005977 Ethylene Substances 0.000 description 14
- 229920000642 polymer Polymers 0.000 description 12
- TVMXDCGIABBOFY-UHFFFAOYSA-N n-Octanol Natural products CCCCCCCC TVMXDCGIABBOFY-UHFFFAOYSA-N 0.000 description 10
- 238000004806 packaging method and process Methods 0.000 description 5
- 229920001577 copolymer Polymers 0.000 description 4
- 229920001519 homopolymer Polymers 0.000 description 4
- 230000004888 barrier function Effects 0.000 description 3
- 239000004604 Blowing Agent Substances 0.000 description 2
- 238000000071 blow moulding Methods 0.000 description 2
- 230000015556 catabolic process Effects 0.000 description 2
- 230000001010 compromised effect Effects 0.000 description 2
- 238000006731 degradation reaction Methods 0.000 description 2
- 239000003599 detergent Substances 0.000 description 2
- 238000009472 formulation Methods 0.000 description 2
- 210000003739 neck Anatomy 0.000 description 2
- 239000000344 soap Substances 0.000 description 2
- 238000012360 testing method Methods 0.000 description 2
- 229920001169 thermoplastic Polymers 0.000 description 2
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 1
- 239000004952 Polyamide Substances 0.000 description 1
- 230000002730 additional effect Effects 0.000 description 1
- 125000004429 atom Chemical group 0.000 description 1
- 238000007664 blowing Methods 0.000 description 1
- 229910052799 carbon Inorganic materials 0.000 description 1
- 230000000052 comparative effect Effects 0.000 description 1
- 239000000470 constituent Substances 0.000 description 1
- 238000011109 contamination Methods 0.000 description 1
- 239000002537 cosmetic Substances 0.000 description 1
- 238000011161 development Methods 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 238000002474 experimental method Methods 0.000 description 1
- 125000005842 heteroatom Chemical group 0.000 description 1
- 125000004435 hydrogen atom Chemical group [H]* 0.000 description 1
- 238000011835 investigation Methods 0.000 description 1
- 229910052751 metal Inorganic materials 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- 150000002739 metals Chemical class 0.000 description 1
- 238000000465 moulding Methods 0.000 description 1
- 239000005022 packaging material Substances 0.000 description 1
- 229920003023 plastic Polymers 0.000 description 1
- 239000004033 plastic Substances 0.000 description 1
- 229920002647 polyamide Polymers 0.000 description 1
- 229920000728 polyester Polymers 0.000 description 1
- 229920000098 polyolefin Polymers 0.000 description 1
- 239000007787 solid Substances 0.000 description 1
- 239000004416 thermosoftening plastic Substances 0.000 description 1
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B1/00—Layered products having a general shape other than plane
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
- B32B27/065—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of foam
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/32—Layered products comprising a layer of synthetic resin comprising polyolefins
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
- B32B5/18—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer of foamed material
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
- B32B5/18—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer of foamed material
- B32B5/20—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer of foamed material foamed in situ
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2250/00—Layers arrangement
- B32B2250/03—3 layers
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2250/00—Layers arrangement
- B32B2250/24—All layers being polymeric
- B32B2250/242—All polymers belonging to those covered by group B32B27/32
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2266/00—Composition of foam
- B32B2266/02—Organic
- B32B2266/0214—Materials belonging to B32B27/00
- B32B2266/025—Polyolefin
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2323/00—Polyalkenes
- B32B2323/04—Polyethylene
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2439/00—Containers; Receptacles
- B32B2439/40—Closed containers
- B32B2439/60—Bottles
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2439/00—Containers; Receptacles
- B32B2439/70—Food packaging
Abstract
The present invention relates to an article for containing liquids, comprising an outer wall, wherein the outer wall is a multi-layer system comprising at least three layers A, B and C in this order, wherein the layer A is suitable for contacting a liquid material that may be contained within the article and forms the inner layer of the multi-layer system, the layer B forms the intermediate layer, and the layer C forms the outer layer of the multi-layer system; wherein: · the layer A comprises a polyethylene A having a density of ≥ 0.940 and ≤ 0.970 g/cm3; · the layer B is a foamed layer comprising a polyethylene composition B having a density of ≥ 0.940 and ≤ 0.970 g/cm3; and · the layer C comprises a polyethylene composition C having a density of ≥ 0.940 and ≤ 0.970 g/cm3. Such article may be produced using a mono-material solution of polyethylene, thereby contributing to the recyclability of the article, whilst providing desirable strength, durability and inertness.
Description
Article comprising recycled and renewable polyethylene.
[0001] The present invention relates to an article, preferably a bottle, comprising recycled and renewable polyethylene. The invention also relates to an extrusion blow-moulding process for the production of such articles.
[0002] For a great variety of applications, including for example as containers for liquid household goods, articles, such as hollow body containers, a particular example of which being bottles of various shapes, are ubiquitously utilised. Examples of household goods that commonly are contained in the articles that are subject of the present invention are liquid foodstuffs, detergents, liquid soap, to name some.
[0003] To qualify for such use, the containers need to comply with a range of specifications. It is for example a requirement that they provide an adequate barrier between the contents of the article and the environment so that degradation of the contents caused by the environment it is subject to is minimised. Furthermore, the container needs to be sufficiently inert to the material contained therein to avoid degradation of the container wall material, as well as contamination of the contents of the container. More requirements apply, including the need that the container needs to be sufficiently shape-stable, and it needs to be able to be produced at attractive process economies.
[0004] Presently, additional properties are being requested of the containers. In view of an ever increasing desire to stimulate circularity, in particular in packaging materials, it is desired that packaging solutions, including hollow body containers, are increasingly light in weight, thereby reducing the amount of material used, they should be suitable for being recycled, and to the extent possible they should be produced using materials that are themselves recycled. At the same time, the further properties as referred to above should not be compromised, as the article still needs to fulfil its purpose as a package.
[0005] In view of the desire for a package to be suitable for being recycled, a particular way to achieve this is via ensuring that the package is essentially made out of material that belongs to a single material family. In the art, many packaging solutions exist where one part of the object is made out of material belonging to a first family of materials, and other parts out of material from a second family. Since it is undesirable at least but often also impossible at most to recycle
materials belonging to different families of materials in a single recycling process, one will understand that there is a strive to manufacture objects that are to be suitable for recycling from materials belonging to a single family to the largest degree possible.
[0006] In packaging, in particular in single-use packaging, this is even more relevant, due to the short service life of the article. Furthermore, in packaging solutions, barrier elements that serve to contain a product quite often are manufactured in the form of multi-layer wall or film solutions; and in such solutions, it is quite common that the different layers of such object wall contain very different types of materials, that are unsuitable for joint recycling. For example, thermoplastic multilayer barrier walls may comprise layers comprising polyolefin materials, layers comprising polyamide materials, and/or layers comprising polyester materials, to name just a few, combined together; wherein each layer serves its own purpose to achieve the ultimate properties that are required for the particular application.
[0007] One will understand that it is impossible to tear apart such layers when preparing materials for recycling. Accordingly, it is desired that the various layers of such application, while together still of such constitution that the required properties of the article are achieved, are of materials belonging to a single family of materials. By so, recycling of the article is greatly facilitated.
[0008] A particular family of materials that one would seek to employ in such solutions are polyethylenes. Polyethylenes are the most ubiquitously used thermoplastic polymer family, due to their vast potential of applications. Mixed plastics recycle streams typically contain a majority portion of polyethylenes. Recycling of polyethylenes can be achieved via a range of recycling technologies, including mechanical recycling and chemical recycling, which is facilitated by the fact that polyethylenes consist essentially of carbon and hydrogen atoms; this contributes to the reduction of the presence of undesirable atoms such as certain heteroatoms and metals in recycling processes such as chemical recycling. For these reasons, it is desirable that articles that need to be suitable for recycling contain a maximised quantity of polyethylene as constituents of their material formulation.
[0009] Accordingly, the development of such mono-material solutions for articles is subject of many investigations. In addition, it needs to be established that the article properties including material strength and durability are not compromised. In the present application, such solution is provided by an article for containing liquids, comprising an outer wall, wherein the outer wall is a
multi-layer system comprising at least three layers A, B and C in this order, wherein the layer A is suitable for contacting a liquid material that may be contained within the article and forms the inner layer of the multi-layer system, the layer B forms the intermediate layer, and the layer C forms the outer layer of the multi-layer system; wherein:
• the layer A comprises a polyethylene A having a density of > 0.940 and < 0.970 g/cm3;
• the layer B is a foamed layer comprising a polyethylene composition B having a density of > 0.940 and < 0.970 g/cm3; and
• the layer C comprises a polyethylene composition C having a density of > 0.940 and < 0.970 g/cm3.
[0010] Such article may be produced using a mono-material solution of polyethylene, thereby contributing to the recyclability of the article, whilst providing desirable strength, durability and inertness.
[0011] Preferably, the article is a hollow body container, more preferably a bottle. The article may for example have an inner volume of > 0.05 and < 5.0 I, preferably of > 0.05 and < 2.0 I.
[0012] The polyethylene A may for example be a homopolymer of ethylene, or a copolymer of ethylene and an a-olefin selected from 1-butene, 1-hexene, 4-methyl-1 -pentene, and 1-octene. For example, the polyethylene A may be a polymer comprising moieties of ethylene and < 5.0 wt % of moieties derived from 1-butene, 1-hexene, 4-methyl-1 -pentene, and 1-octene, with regard to the total weight of the polymer.
[0013] The polyethylene composition B may for example comprise a homopolymer of ethylene, or a copolymer of ethylene and an a-olefin selected from 1-butene, 1-hexene, 4-methyl-1- pentene, and 1-octene. For example, the polyethylene composition B may comprise a polymer comprising moieties of ethylene and < 5.0 wt % of moieties derived from 1-butene, 1-hexene, 4- methyl-1 -pentene, and 1-octene, with regard to the total weight of the polymer. For example, the polyethylene composition B may comprise, with regard to the total weight of the polyethylene composition B, > 30.0 wt% and < 70.0 wt% of a polymer comprising moieties of ethylene and < 5.0 wt % of moieties derived from 1-butene, 1-hexene, 4-methyl-1 -pentene, and 1-octene, with regard to the total weight of the polymer.
[0014] For example, the polyethylene composition B may comprise > 80.0 wt% of polyethylenes, preferably > 90.0 wt%, with regard to the total weight of the polyethylene composition B.
[0015] The polyethylene composition B may for example comprise < 5.0 wt% of polypropylene, preferably > 0.1 and < 5.0 wt%, more preferably > 0.1 and < 3.0 wt%, with regard to the total weight of the polyethylene composition B.
[0016] The layer B may for example have a foam density of > 0.20 and < 0.80 g/cm3, preferably > 0.40 and < 0.75 g/cm3, more preferably > 0.50 and < 0.75 g/cm3, even more preferably of > 0.60 and < 0.75 g/cm3, yet even more preferably of > 0.65 and < 0.75 g/cm3, as determined in accordance with the method of ISO 845 (2006). It is preferred that the layer B comprises < 10.0 wt% of talc, more preferably > 0.1 and < 5.0 wt%, even more preferably > 0.5 and < 5.0 wt%, with regard to the total weight of the layer B.
[0017] The polyethylene composition C may for example comprise a homopolymer of ethylene, or a copolymer of ethylene and an a-olefin selected from 1-butene, 1-hexene, 4-methyl-1- pentene, and 1-octene. For example, the polyethylene composition C may comprise a polymer comprising moieties of ethylene and < 5.0 wt % of moieties derived from 1-butene, 1-hexene, 4- methyl-1 -pentene, and 1-octene, with regard to the total weight of the polymer. For example, the polyethylene composition C may comprise, with regard to the total weight of the polyethylene composition B, > 30.0 wt% and < 70.0 wt% of a polymer comprising moieties of ethylene and < 5.0 wt % of moieties derived from 1-butene, 1-hexene, 4-methyl-1 -pentene, and 1-octene, with regard to the total weight of the polymer.
[0018] For example, the polyethylene composition C may comprise > 80.0 wt% of polyethylenes, preferably > 90.0 wt%, with regard to the total weight of the polyethylene composition C.
[0019] The polyethylene A may for example be a homopolymer of ethylene, or a copolymer of ethylene and an a-olefin selected from 1-butene, 1-hexene, 4-methyl-1 -pentene, and 1-octene. For example, the polyethylene A may be a polymer comprising moieties of ethylene and < 5.0 wt % of moieties derived from 1-butene, 1-hexene, 4-methyl-1 -pentene, and 1-octene, with regard to the total weight of the polymer.
[0020] The polyethylene composition C may for example comprise < 5.0 wt% of polypropylene, preferably > 0.1 and < 5.0 wt%, more preferably > 0.1 and < 3.0 wt%, with regard to the total weight of the polyethylene composition C.
[0021] For example, the polyethylene composition B may have a melt mass-flow rate as determined in accordance with ISO 1133-1 (2011) at 190°C and 21.6 kg load of > 10.0 and < 70.0 g/10 min, preferably of > 20.0 and < 60.0 g/10 min, more preferably of > 20.0 and < 50.0 g/10 min.
[0022] For example, the polyethylene composition B may have a melt mass-flow rate as determined in accordance with ISO 1133-1 (2011) at 190°C and 5.0 kg load of > 0.5 and < 5.0 g/10 min, preferably of > 0.5 and < 3.0 g/10 min, more preferably of > 0.5 and < 2.0 g/10 min.
[0023] For example, the polyethylene composition B may have a density of > 960 and < 970 kg/m3. For example, the polyethylene composition C may have a density of > 960 and < 970 kg/m3. Density of the polyethylenes or polyethylene compositions may be determined in accordance with ISO 1183-1 (2019).
[0024] For example, the polyethylene composition B may have a melt mass-flow rate as determined in accordance with ISO 1133-1 (2011) at 190°C and 2.1 kg load of > 0.15 and < 0.5 g/10 min, preferably of > 0.15 and < 0.4 g/10 min, more preferably of > 0.15 and < 0.3 g/10 min.
[0025] For example, the polyethylene composition C may have a melt mass-flow rate as determined in accordance with ISO 1133-1 (2011) at 190°C and 21.6 kg load of > 10.0 and < 70.0 g/10 min, preferably of > 20.0 and < 60.0 g/10 min, more preferably of > 20.0 and < 50.0 g/10 min.
[0026] For example, the polyethylene composition C may have a melt mass-flow rate as determined in accordance with ISO 1133-1 (2011) at 190°C and 5.0 kg load of > 0.5 and < 5.0 g/10 min, preferably of > 0.5 and < 3.0 g/10 min, more preferably of > 0.5 and < 2.0 g/10 min.
[0027] For example, the polyethylene composition C may have a melt mass-flow rate as determined in accordance with ISO 1133-1 (2011) at 190°C and 2.1 kg load of > 0.15 and < 0.5 g/10 min, preferably of > 0.15 and < 0.4 g/10 min, more preferably of > 0.15 and < 0.3 g/10 min.
[0028] For example, the polyethylene A may have a melt mass-flow rate as determined in accordance with ISO 1133-1 (2011) at 190°C and 21.6 kg load of > 10.0 and < 70.0 g/10 min, preferably of > 20.0 and < 60.0 g/10 min, more preferably of > 20.0 and < 50.0 g/10 min.
[0029] For example, the polyethylene A may have a melt mass-flow rate as determined in accordance with ISO 1133-1 (2011) at 190°C and 5.0 kg load of > 0.5 and < 5.0 g/10 min, preferably of > 0.5 and < 3.0 g/10 min, more preferably of > 0.5 and < 2.0 g/10 min.
[0030] For example, the polyethylene A may have a melt mass-flow rate as determined in accordance with ISO 1133-1 (2011) at 190°C and 2.1 kg load of > 0.15 and < 0.5 g/10 min, preferably of > 0.15 and < 0.4 g/10 min, more preferably of > 0.15 and < 0.3 g/10 min.
[0031] The polyethylene composition B may for example be a composition comprising postconsumer mechanically recycled polyethylene, preferably comprising > 30.0 and < 60.0 wt% of post-consumer mechanically recycled polyethylene.
[0032] The polyethylene composition C may for example be a composition comprising postconsumer mechanically recycled polyethylene, preferably comprising > 30.0 and < 60.0 wt% of post-consumer mechanically recycled polyethylene.
[0033] The polyethylene A may for example be a polyethylene obtained by chemical recycling of polyethylene, or by a synthesis process using a biorenewable hydrocarbon feedstock.
[0034] In the article, the multi-layer system may for example have a thickness of > 0.5 and < 2.5 mm, preferably of > 0.7 and < 2.0, more preferably of > 0.7 and < 1.5 mm, even more preferably of > 0.9 and < 1.5 mm. The layer A may for example have a thickness of > 0.1 and < 0.3 mm, preferably of > 0.15 and < 0.25 mm. The layer B may for example have a thickness of > 0.3 and < 1.0 mm, preferably of > 0.4 and < 1.0 mm, more preferably of > 0.4 and < 0.8 mm, even more preferably of > 0.5 and < 0.7 mm. The layer C may for example have a thickness of > 0.1 and< 0.3 mm, preferably of > 0.15 and < 0.25 mm.
[0035] For example, the multi-layer system may have a thickness of > 0.7 and < 1.5 mm, preferably of > 0.9 and < 1.5 mm, wherein the layer A has a thickness of > 0.15 and < 0.25 mm, the layer B has a thickness of > 0.4 and < 1.0 mm, preferably of > 0.5 and < 0.7 mm, and the layer C has a thickness of > 0.15 and < 0.25 mm.
[0036] The article may for example be produced by an extrusion blow-moulding process.
[0037] In an embodiment, the present invention also relates to a process for production of an article according to the invention, wherein the process involves the steps of:
(i) producing a tubular shaped object comprising the layers A, B and C via extrusion, preferably via co-extrusion, more preferably continuous co-extrusion;
(ii) enclosing the tubular shaped object with a mould having the exterior form of the article;
(iii) supplying a pressurised gas to the inner volume of the tubular shaped object so that the tubular shape expands to fill the mould to the form of the article;
(iv) cooling the mould to solidify the outer wall; and
(v) removing the article from the mould.
[0038] The tubular shaped object may herein also be referred to as a parison.
[0039] In step (i) the co-extrusion of the tubular shaped object may for example involve supplying the materials that are to constitute the layers A, B and C in molten state via an extrusion head comprising split annular flow channels for each of the layers A, B and C, wherein the annular flows of extruded material are contacted upon exiting the extrusion head to form the tubular shaped object comprising the layers A, B and C.
[0040] In step (i), a foaming agent may be supplied to the material that forms layer B, wherein the material that forms layer B is in a molten state at the time of supply of the foaming agent, preferably wherein the foaming agent in nitrogen.
[0041] An exemplary embodiment of the article is presented in Fig. 1. Therein, a cross-section of an article according to the invention (1) is shown. The article of Fig. 1 comprises an outside wall (2), an outer layer (3) corresponding to layer C of the article of the invention, a foamed layer
(4) corresponding to the intermediate layer B of the article of the invention, an inner layer (5) corresponding to layer A of the article of the invention, and an inside wall (6).
[0042] In a certain embodiment, the invention also relates to the use of a multi-layer system comprising at least three layers A, B and C in this order, wherein the layer A is suitable for contacting a liquid material that may be contained within the article and forms the inner layer of the multi-layer system, the layer B forms the intermediate layer, and the layer C forms the outer layer of the multi-layer system; wherein:
• the layer A comprises a polyethylene A having a density of > 0.940 and < 0.970 g/cm3;
• the layer B is a foamed layer, having a foam density of > 0.65 and < 0.75 g/cm3, as determined in accordance with the method of ISO 845 (2006), comprising a polyethylene composition B having a density of > 0.940 and < 0.970 g/cm3, preferably of > 0.960 and < 0.970 g/cm3; and
• the layer C comprises a polyethylene composition C having a density of > 0.940 and < 0.970 g/cm3, preferably of > 0.960 and < 0.970 g/cm3; the density being determined in accordance with ISO 1183-1 (2019); for improvement of the load bearing properties of an extrusion blow-moulded article, preferably a hollow body container.
[0043] The invention will now be illustrated by the following non-limiting examples.
[0044] Each of T5E01BG, T5E01BN, T5E01BB and T5E01BW contained ca. 1 wt% of polypropylene. [0045] Experiments were conducted by co-extrusion of the above-listed materials on a blowmoulding machine equipped with three extruders in combination with a three-layer extrusion head and a dynamic mixer with gas dosing between the extruder and the extrusion head. The main extruder B for the intermediate layer B was a 60/25D extruder; the extruder A for the inner layer A was a 25/25D extruder; the extruder C for the outer layer C was a 30/25D extruder. Multi-layer bottles having a volume of 70 ml were produced. Nitrogen was used as foaming agent, also referred to as blowing agent, for the layer B. The total throughput of the extruders was 4.2 kg/h; the melt temperature of extruder A was 188°C; the melt temperature of extruder B was 190°C; the melt temperature of extruder C was 187°C. The temperature of the extrusion head was 160°C. A 3-layer parison of diameter 20 mm was formed by extrusion according to the formulations in the table below:
Wherein
• MI2 is the melt mass-flow rate determined at 2.16 kg, 190°C, expressed in g/10 min, in accordance with ISO 1133 (2011);
• MI5 is the melt mass-flow rate as determined at 5.0 kg, 190°C, expressed in g/10 min, in accordance with ISO 1133 (2011);
• MI21 is the melt mass-flow rate as determined at 21 .6 kg, 190°C, expressed in g/10 min, in accordance with ISO 1133 (2011);
• density is the density of the polyethylene, as determined in accordance with ISO 1183-1 (2019);
• all the percentage of the composition of the layers B are in wt% with regard to the total weight of the layer B.
[0046] Subsequently, the parison was subjected to blow moulding in a mould at ambient temperature by applying a blowing pressure between 2 and 6 bar for 8 s. By this process, 70 ml bottles were formed having a wall thickness of 1 mm, of which 0.2 mm layer A, 0.6 mm layer B, and 0.2 mm layer C. The foamed layer B has a foam density of 0.70 g/cm3. The moulded bottles had an inner wall that is inert to required products that are to be contained in such bottles, such as foodstuffs, detergents, soaps and cosmetic products. The bottles further showed desirable load bearing strengths of over 300 N; the load bearing strength being defined as the load at which the bottle neck collapses as a result of the load exerted onto it.
[0047] For comparative purposes, bottles were prepared according to the extrusion and moulding conditions set out above, with the exception that no blowing agent was added; accordingly, the moulded bottles did not contain a foamed intermediate layer B, but rather a solid layer B. When subjecting these bottles to load testing, it was observed that the bottles did not pass a test at load of 300 N; the bottle necks collapsed under such load. It was determined that to comply with this load bearing requirement, the weight of the layer B had to be increased to such extent that the total weight of the bottle increased by 10%.
[0048] Accordingly, it can be understood that the article according to the invention allows for providing desirable load bearing properties at reduced weight of the article.
Claims
Claims
1. Article for containing liquids, comprising an outer wall, wherein the outer wall is a multilayer system comprising at least three layers A, B and C in this order, wherein the layer A is suitable for contacting a liquid material that may be contained within the article and forms the inner layer of the multi-layer system, the layer B forms the intermediate layer, and the layer C forms the outer layer of the multi-layer system; wherein:
• the layer A comprises a polyethylene A having a density of > 0.940 and < 0.970 g/cm3;
• the layer B is a foamed layer comprising a polyethylene composition B having a density of > 0.940 and < 0.970 g/cm3, preferably of > 0.960 and < 0.970 g/cm3; and
• the layer C comprises a polyethylene composition C having a density of > 0.940 and < 0.970 g/cm3, preferably of > 0.960 and < 0.970 g/cm3; the density being determined in accordance with ISO 1183-1 (2019).
2. Article according to claim 1 , wherein the article is a hollow body container, preferably a bottle.
3. Article according to claim 2, wherein the article has an inner volume of > 0.05 and < 5.0 I, preferably of > 0.05 and < 2.0 I.
4. Article according to any one of claims 1-3, wherein the layer B has a foam density of > 0.20 and < 0.80 g/cm3, preferably 0.40 and < 0.75 g/cm3, more preferably of > 0.65 and < 0.75 g/cm3, as determined in accordance with the method of ISO 845 (2006).
5. Article according to any one of claims 1-4, wherein the polyethylene composition B comprises < 5.0 wt% of polypropylene, preferably > 0.1 and < 5.0 wt%, more preferably > 0.1 and < 3.0 wt%, with regard to the total weight of the polyethylene composition B.
6. Article according to any one of claims 1-5, wherein the layer B comprises < 10.0 wt% of talc, preferably > 0.1 and < 5.0 wt%, more preferably > 0.5 and < 5.0 wt%, with regard to the total weight of the layer B.
Article according to any one of claims 1-6, wherein:
• the polyethylene composition B has a melt mass-flow rate as determined in accordance with ISO 1133-1 (2011) at 190°C and 21.6 kg load of > 10.0 and < 70.0 g/10 min; and/or
• the polyethylene composition C has a melt mass-flow rate as determined in accordance with ISO 1133-1 (2011) at 190°C and 21.6 kg load of > 10.0 and < 70.0 g/10 min; and/or
• the polyethylene A has a melt mass-flow rate as determined in accordance with ISO 1133-1 (2011) at 190°C and 21.6 kg load of > 10.0 and < 70.0 g/10 min. Article according to any one of claims 1-7, wherein the polyethylene composition B is a composition comprising post-consumer mechanically recycled polyethylene, preferably comprising > 30.0 and < 60.0 wt% of post-consumer mechanically recycled polyethylene; and/or wherein the polyethylene composition C is a composition comprising post-consumer mechanically recycled polyethylene, preferably comprising > 30.0 and < 60.0 wt% of postconsumer mechanically recycled polyethylene. Article according to any one of claims 1-8, wherein the polyethylene A is a polyethylene obtained by chemical recycling of polyethylene, or by a synthesis process using a biorenewable hydrocarbon feedstock. Article according to any one of claims 1-9, wherein the multi-layer system has a thickness of > 0.5 and < 2.5 mm, preferably of > 0.9 and < 1.5 mm, preferably wherein:
• the layer A has a thickness of > 0.1 and< 0.3 mm, more preferably of > 0.15 and < 0.25 mm; and
• the layer B has a thickness of > 0.3 and < 1.0 mm, more preferably of > 0.5 and < 0.7 mm; and
• the layer C has a thickness of > 0.1 and< 0.3 mm, more preferably of > 0.15 and < 0.25 mm. Article according to any one of claims 1-10, wherein the article is produced by an extrusion blow-moulding process.
12. Process for production of an article according to any one of claims 1-11 , wherein the process involves the steps of:
(i) producing a tubular shaped object comprising the layers A, B and C via extrusion, preferably via co-extrusion, more preferably continuous co-extrusion;
(ii) enclosing the tubular shaped object with a mould having the exterior form of the article;
(iii) supplying a pressurised gas to the inner volume of the tubular shaped object so that the tubular shape expands to fill the mould to the form of the article;
(iv) cooling the mould to solidify the outer wall; and
(v) removing the article from the mould.
13. Process according to claim 12, where in step (i) the co-extrusion of the tubular shaped object involves supplying the materials that are to constitute the layers A, B and C in molten state via an extrusion head comprising split annular flow channels for each of the layers A, B and C, wherein the annular flows of extruded material are contacted upon exiting the extrusion head to form the tubular shaped object comprising the layers A, B and C.
14. Process according to any one of claims 12-13, wherein in step (i), a foaming agent is supplied to the material that forms layer B, wherein the material that forms layer B is in a molten state at the time of supply of the foaming agent, preferably wherein the foaming agent in nitrogen.
15. Use of a multi-layer system comprising at least three layers A, B and C in this order, wherein the layer A is suitable for contacting a liquid material that may be contained within the article and forms the inner layer of the multi-layer system, the layer B forms the intermediate layer, and the layer C forms the outer layer of the multi-layer system; wherein:
• the layer A comprises a polyethylene A having a density of > 0.940 and < 0.970 g/cm3;
• the layer B is a foamed layer, having a foam density of > 0.65 and < 0.75 g/cm3, as determined in accordance with the method of ISO 845 (2006), comprising a
polyethylene composition B having a density of > 0.940 and < 0.970 g/cm3, preferably of > 0.960 and < 0.970 g/cm3; and
• the layer C comprises a polyethylene composition C having a density of > 0.940 and < 0.970 g/cm3, preferably of > 0.960 and < 0.970 g/cm3; the density being determined in accordance with ISO 1183-1 (2019); for improvement of the load bearing properties of an extrusion blow-moulded article, preferably a hollow body container.
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
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EP22201692 | 2022-10-14 | ||
EP22201692.5 | 2022-10-14 |
Publications (1)
Publication Number | Publication Date |
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WO2024078911A1 true WO2024078911A1 (en) | 2024-04-18 |
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ID=84332118
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
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PCT/EP2023/077253 WO2024078911A1 (en) | 2022-10-14 | 2023-10-02 | Article comprising recycled and renewable polyethylene |
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WO (1) | WO2024078911A1 (en) |
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2023
- 2023-10-02 WO PCT/EP2023/077253 patent/WO2024078911A1/en unknown
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