Recyclate Blends
AssigneeMetabolix, Inc.
InventorsYelena KANN, David BOUDREAU
Life of this patent
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Abstract
Compositions comprising recyclate blends of polymer recyclate and polyester additives are described. In certain embodiments, the polyester additive is a PHA such as a poly-3-hydroxybutyrate-co-4-hydroxybutyrate copolymer having a weight percent 4-hydroxybutyrate of 8.5-45%. In other embodiments the PHA is mixed with the recyclate polymer at concentrations of 10-50% by weight of the recyclate blend. Methods of making the compositions of the invention are also described. The invention also includes articles made from the recyclate blends.
Claims47
A composition comprising a recyclate blend of a recyclate polymer and a polyester additive, wherein the recylate polymer is a recyclate poly (vinyl chloride) (PVC), recyclate nylon 6, recyclate polyoxymethylene (POM) or recyclate poly(methyl methacrylate), and the polyester additive comprises a PHA, an aliphatic-aromatic polyester incorporating diols and diacids, a polybutylene-succinate or a polybutylene-succinate-adipate, and combinations thereof.
The composition of any one of the preceding claims, wherein the recyclate polymer is reprocessed or regrind polymer.
The composition of any one of the preceding claims, wherein polyester additive comprises a copolymer blend which includes at least one poly-3-hydroxybutytrate-co-4-polyhydroxybutyrate copolymer and a poly-3-hydroxybutyrate homopolymer.
The composition of any one of the preceding claims, wherein the polyester additive is a PHA having an average molecular weight range of about 250,000 to about 2.5 million g/mole.
The composition of any one of the preceding claims, wherein the polyester additive is a PHA having a weight % 4HB of about 8% to about 50% in the PHA composition.
The composition of any one of the preceding claims, wherein the composition has a biobased content of 8.5-46%.
The composition of any one of the preceding claims, wherein the polyester additive is a PHA and the recyclate blend comprises about 10% to about 50% by weight of the PHA
The composition of any one of the preceding claims, wherein the polyester additive is a PHA and the recyclate blend comprises about 10% to about 40% by weight of the PHA.
The composition of any one of the preceding claims, wherein the polyester additive is a PHA and the recyclate blend comprises about 20% to about 30% by weight of the PHA.
The composition of any one of the preceding claims, further comprising one or more additives.
The composition of any one of the preceding claims, wherein the recyclate blend has improved material property performance compared to the recyclate polymer.
The composition of any one of the preceding claims, wherein the material property performance is improved when the recyclate blend has at least one of the following:
- a tensile modulus, tensile stress at yield, tensile strain at yield, tensile stress at break, tensile stress at break, energy at break, or tear, greater than the recyclate polymer.
The composition of any one of the preceding claims, wherein the composition has improved tensile and tear properties.
The composition of any of the preceding claims, wherein the recyclate polymer is recyclate PVC and the polyester additive is a PHA and the recyclate PVC and PHA polymer are miscible.
The composition of any of the preceding claims, wherein the recyclate blend has a biobased content of 8.5-46%.
The composition of any of the preceding claims, wherein between about 40% and about 100% biobased content of the recyclate blend is biobased PHA.
The composition of any of the preceding claims, wherein the polyester additive is biobased PHA comprising a poly(3-hydroxybutyrate) homopolymer, a poly(3-hydroxybutyrate-co-4-hydroxybutyrate), a poly(3-hydroxybutyrate-co-3-hydroxyvalerate), a poly(3-hydroxybutyrate-co-5-hydroxyvalerate), or a poly(3-hydroxybutyrate-co-3-hydroxyhexanoate) with the proviso that the PHA composition is not 100% poly(3-hydroxybutyrate) homopolymer or 100% poly(3-hydroxybutyrate-co-3-hydroxyvalerate).
The composition of any of the preceding claims, wherein the polyester additive is biobased PHA comprising a poly(3-hydroxybutyrate) homopolymer, a poly(3-hydroxybutyrate-co-4-hydroxybutyrate) with 5% to 15% 4-hydroxybutyrate content) with 5% to 22% 3-hydroxyvalerate content, a poly(3-hydroxybutyrate-co-5-hydroxyvalerate) with 5% to 15% 5-hydroxyvalerate content, or a poly(3-hydroxybutyrate-co-3-hydroxyhexanoate) with 3% to 15% 3-hydroxyhexanoate content.
The composition of any of the preceding claims, wherein the polyester additive is biobased PHA comprising a first polyhydroxyalkanoate blended with a second polyhydroxyalkanoate, wherein (1) the first polyhydroxyalkanoate is a poly(3-hydroxybutyrate) homopolymer and the second polyhydroxyalkanoate is a poly(3-hydroxybutyrate-co-4-hydroxybutyrate);
- (2) the first polyhydroxyalkanoate is a poly(3-hydroxybutyrate) homopolymer and the second polyhydroxyalkanoate is a poly(3-hydroxybutyrate-co-3-hydroxyvalerate);
- (3) the first polyhydroxyalkanoate is a poly(3-hydroxybutyrate) homopolymer and the second polyhydroxyalkanoate is a poly(3-hydroxybutyrate-co-3-hydroxyhexanoate);
- (4) the first polyhydroxyalkanoate is a poly(3-hydroxybutyrate-co-4-hydroxybutyrate) and the second polyhydroxyalkanoate is a poly(3-hydroxybutyrate-co-3-hydroxyvalerate));
- (5) the first polyhydroxyalkanoate is a poly(3-hydroxybutyrate-co-4-hydroxybutyrate) and the second polyhydroxyalkanoate is a poly(3-hydroxybutyrate-co-3-hydroxyhexanote;
- or (6) the first polyhydroxyalkanoate is a poly(3-hydroxybutyrate-co-3-hydroxyvalerate) and the second polyhydroxyalkanoate is a poly(3-hydroxybutyrate-co-3-hydroxyhexanoate).
The composition of any of the preceding claims, wherein the polyester additive is biobased PHA comprising a first polyhydroxyalkanoate blended with a second polyhydroxyalkanoate, wherein (1) the first polyhydroxyalkanoate is a poly(3-hydroxybutyrate) homopolymer and the second polyhydroxyalkanoate is a poly(3-hydroxybutyrate-co-4-hydroxybutyrate) with a 5% to 15% 4-hydroxybutyrate content;
- (2) the first polyhydroxyalkanoate is a poly(3-hydroxybutyrate) homopolymer and the second polyhydroxyalkanoate is a poly(3-hydroxybutyrate-co-3-hydroxyvalerate) with a 5% to 22% 3-hydroxyvalerate content;
- (3) the first polyhydroxyalkanoate is a poly(3-hydroxybutyrate) homopolymer and the second polyhydroxyalkanoate is a poly(3-hydroxybutyrate-co-3-hydroxyhexanoate) with a 3% to 15% 3-hydroxyhexanoate content;
- (4) the first polyhydroxyalkanoate is a poly(3-hydroxybutyrate-co-4-hydroxybutyrate) with a 5% to 15% 4-hydroxybutyrate content and the second polyhydroxyalkanoate is a a poly(3-hydroxybutyrate-co-3-hydroxyvalerate) with a 5% to 22% 3-hydroxyvalerate content;
- (5) the first polyhydroxyalkanoate is a poly(3-hydroxybutyrate-co-4-hydroxybutyrate) with 5% to 15% 4-hydroxybutyrate content and the second polyhydroxyalkanoate is a poly(3-hydroxybutyrate-co-3-hydroxyhexanoate) with a 3% to 15% 3-hydroxyhexanoate content;
- or (6) the first polyhydroxyalkanoate is a poly(3-hydroxybutyrate-co-3-hydroxyvalerate) with a 5% to 22% 3-hydroxyvalerate content and the second polyhydroxyalkanoate is a poly(3-hydroxybutyrate-co-3-hydroxyhexanoate) with a 3% to 15% 3-hydroxyhexanoate content.
The composition of any of the preceding claims, wherein the polyester additive is biobased PHA comprising a first polyhydroxyalkanoate blended with a second polyhydroxyalkanoate, wherein (1) the first polyhydroxyalkanoate is a poly(3-hydroxybutyrate) homopolymer and the second polyhydroxyalkanoate is a poly(3-hydroxybutyrate-co-4-hydroxybutyrate) and the weight of the first polyhydroxyalkanoate is 5% to 95% of the combined weight of the first polyhydroxyalkanoate and second polyhydroxyalkanoate;
- (2) the first polyhydroxyalkanoate is a poly(3-hydroxybutyrate) homopolymer and the second polyhydroxyalkanoate is a poly(3-hydroxybutyrate-co-3-hydroxyvalerate) and the weight of the first polyhydroxyalkanoate is 5% to 95% of the combined weight of the first polyhydroxyalkanoate and the second polyhydroxyalkanoate (3) the first polyhydroxyalkanoate is a poly(3-hydroxybutyrate) homopolymer and the second polyhydroxyalkanoate is a poly(3-hydroxybutyrate-co-3-hydroxyhexanoate) and the weight of the first polyhydroxyalkanoate is 5% to 95% of the combined weight of the first polyhydroxyalkanoate and the second polyhydroxyalkanoate (4) the first polyhydroxyalkanoate is a poly(3-hydroxybutyrate-co-4-hydroxybutyrate) and the second polyhydroxyalkanoate is a poly(3-hydroxybutyrate-co-3-hydroxyvalerate) and the weight of the first polyhydroxyalkanoate is 5% to 95% of the combined weight of the first polyhydroxyalkanoate and the second polyhydroxyalkanoate (5) the first polyhydroxyalkanoate is a poly(3-hydroxybutyrate-co-4-hydroxybutyrate) and the second polyhydroxyalkanoate is a poly(3-hydroxybutyrate-co-3-hydroxyhexanoate) and the weight of the first polyhydroxyalkanoate is 5% to 95% of the combined weight of the first polyhydroxyalkanoate and the second polyhydroxyalkanoate;
- or (6) the first polyhydroxyalkanoate is a poly(3-hydroxybutyrate-co-3-hydroxyvalerate) and the second polyhydroxyalkanoate is a poly(3-hydroxybutyrate-co-3-hydroxyhexanoate) and the weight of the first polyhydroxyalkanoate is 5% to 95% of the combined weight of the first polyhydroxyalkanoate and the second polyhydroxyalkanoate.
The composition of any of the preceding claims, wherein the polyester additive is biobased PHA comprising a first polyhydroxyalkanoate blended with a second polyhydroxyalkanoate, wherein (1) the first polyhydroxyalkanoate is a poly(3-hydroxybutyrate) homopolymer and the second polyhydroxyalkanoate is a poly(3-hydroxybutyrate-co-4-hydroxybutyrate) with a 20-50% 4-hydroxybutyrate content;
- (2) the first polyhydroxyalkanoate is a poly(3-hydroxybutyrate) homopolymer and the second polyhydroxyalkanoate is a poly(3-hydroxybutyrate-co-5-hydroxyvalerate) with a 20% to 50% 5-hydroxyvalerate content;
- (3) the first polyhydroxyalkanoate is a poly(3-hydroxybutyrate) homopolymer and the second polyhydroxyalkanoate is a poly(3-hydroxybutyrate-co-3-hydroxyhexanoate) having a 5%-50% 3-hydroxyhexanoate content;
- (4) the first polyhydroxyalkanoate is a poly(3-hydroxybutyrate-co-4-hydroxybutyrate) with a 5% to 15% 4-hydroxybutyrate content and the second polyhydroxyalkanoate is a poly(3-hydroxybutyrate-co-4-hydroxybutyrate) with a 20-50% 4-hydroxybutyrate content;
- (5) the first polyhydroxyalkanoate is a poly(3-hydroxybutyrate-co-4-hydroxybutyrate) with a 5% to 15% 4-hydroxybutyrate content and the second polyhydroxyalkanoate is a poly(3-hydroxybutyrate-co-5-hydroxyvalerate) with a 20% to 50% 5-hydroxyvalerate content;
- (6) the first polyhydroxyalkanoate is a poly(3-hydroxybutyrate-co-4-hydroxybutyrate) with 5% to 15% 4-hydroxybutyrate content and the second polyhydroxyalkanoate is a poly(3-hydroxybutyrate-co-3-hydroxyhexanoate) having a 5%-50% 3-hydroxyhexanoate content;
- (7) the first polyhydroxyalkanoate is a poly(3-hydroxybutyrate-co-3-hydroxyvalerate) with a 5% to 22% 3-hydroxyvalerate content and the second polyhydroxyalkanoate is a poly(3-hydroxybutyrate-co-4-hydroxybutyrate) with a 20-50% 4-hydroxybutyrate content;
- (8) the first polyhydroxyalkanoate is a poly(3-hydroxybutyrate-co-3-hydroxyvalerate) with a 5% to 22% 3-hydroxyvalerate content and the second polyhydroxyalkanoate is a poly(3-hydroxybutyrate-co-5-hydroxyvalerate) with a 20% to 50% 5-hydroxyvalerate content;
- (9) the first polyhydroxyalkanoate is a poly(3-hydroxybutyrate-co-3-hydroxyvalerate) with a 5% to 22% 3-hydroxyvalerate content and the second polyhydroxyalkanoate is a poly(3-hydroxybutyrate-co-3-hydroxyhexanoate) having a 5%-50% 3-hydroxyhexanoate content;
- (10) the first polyhydroxyalkanoate is a poly(3-hydroxybutyrate-co-3-hydroxyhexanoate) with a 3% to 15% 3-hydroxyhexanoate content and the second polyhydroxyalkanoate is a poly(3-hydroxybutyrate-co-4-hydroxybutyrate) with a 20-50% 4-hydroxybutyrate content;
- (11) the first polyhydroxyalkanoate is a poly(3-hydroxybutyrate-co-3-hydroxyhexanoate) with a 3% to 15% 3-hydroxyhexanoate content and the second polyhydroxyalkanoate is a poly(3-hydroxybutyrate-co-5-hydroxyvalerate) with a 20% to 50% 5-hydroxyvalerate;
- or (12) the first polyhydroxyalkanoate is a poly(3-hydroxybutyrate-co-3-hydroxyhexanoate) with a 3% to 15% 3-hydroxyhexanoate content and the second polyhydroxyalkanoate is a poly(3-hydroxybutyrate-co-3-hydroxyhexanoate) having a 5%-50% 3-hydroxyhexanoate content.
The composition of any of the preceding claims, wherein the polyester additive is biobased PHA comprising a first polyhydroxyalkanoate blended with a second polyhydroxyalkanoate, wherein (1) the first polyhydroxyalkanoate is a poly(3-hydroxybutyrate) homopolymer and the second polyhydroxyalkanoate is a poly(3-hydroxybutyrate-co-4-hydroxybutyrate) with a 20-50% 4-hydroxybutyrate content and the weight of the first polyhydroxyalkanoate is 5% to 95% of the combined weight of the first polyhydroxyalkanoate and the second polyhydroxyalkanoate (2) the first polyhydroxyalkanoate is a poly(3-hydroxybutyrate) homopolymer and the second polyhydroxyalkanoate is a poly(3-hydroxybutyrate-co-3-hydroxyvalerate) with a 20% to 50% 5-hydroxyvalerate content and the weight of the first polyhydroxyalkanoate is 5% to 95% of the combined weight of the first polyhydroxyalkanoate and the second polyhydroxyalkanoate (3) the first polyhydroxyalkanoate is a poly(3-hydroxybutyrate) homopolymer and the second polyhydroxyalkanoate is a poly(3-hydroxybutyrate-co-3-hydroxyhexanoate) having a 5%-50% 3-hydroxyhexanoate content and the weight of the first polyhydroxyalkanoate is 5% to 95% of the combined weight of the first polyhydroxyalkanoate and the second polyhydroxyalkanoate (4) the first polyhydroxyalkanoate is a poly(3-hydroxybutyrate-co-4-hydroxybutyrate) with a 5% to 15% 4-hydroxybutyrate content and the second polyhydroxyalkanoate is a poly(3-hydroxybutyrate-co-4-hydroxybutyrate) with a 20-50% 4-hydroxybutyrate content and the weight of the first polyhydroxyalkanoate is 5% to 95% of the combined weight of the first polyhydroxyalkanoate and the second polyhydroxyalkanoate (5) the first polyhydroxyalkanoate is a poly(3-hydroxybutyrate-co-4-hydroxybutyrate) with a 5% to 15% 4-hydroxybutyrate content and the second polyhydroxyalkanoate is a poly(3-hydroxybutyrate-co-5-hydroxyvalerate) with a 20% to 50% 5-hydroxyvalerate and the weight of the first polyhydroxyalkanoate is 5% to 95% of the combined weight of the first polyhydroxyalkanoate and the second polyhydroxyalkanoate (6) the first polyhydroxyalkanoate is a poly(3-hydroxybutyrate-co-4-hydroxybutyrate) with a 5% to 15% 4-hydroxybutyrate content and the second polyhydroxyalkanoate is a poly(3-hydroxybutyrate-co-3-hydroxyhexanoate) having a 5%-50% 3-hydroxyhexanoate content and the weight of the first polyhydroxyalkanoate is 5% to 95% of the combined weight of the first polyhydroxyalkanoate and the second polyhydroxyalkanoate (7) the first polyhydroxyalkanoate is a poly(3-hydroxybutyrate-co-3-hydroxyvalerate) with a 5% to 22% 3-hydroxyvalerate content and the second polyhydroxyalkanoate is a poly(3-hydroxybutyrate-co-4-hydroxybutyrate) with a 20-50% 4-hydroxybutyrate content and the weight of the first polyhydroxyalkanoate is 5% to 95% of the combined weight of the first polyhydroxyalkanoate and the second polyhydroxyalkanoate(8) the first polyhydroxyalkanoate is a poly(3-hydroxybutyrate-co-3-hydroxyvalerate) with a 5% to 22% 3-hydroxyvalerate content and the second polyhydroxyalkanoate is a poly(3-hydroxybutyrate-co-5-hydroxyvalerate) with a 20% to 50% 5-hydroxyvalerate and the weight of the first polyhydroxyalkanoate is 5% to 95% of the combined weight of the first polyhydroxyalkanoate and the second polyhydroxyalkanoate (9) the first polyhydroxyalkanoate is a poly(3-hydroxybutyrate-co-3-hydroxyvalerate) with a 5% to 22% 3-hydroxyvalerate content and the second polyhydroxyalkanoate is a poly(3-hydroxybutyrate-co-3-hydroxyhexanoate) having a 5%-50% 3-hydroxyhexanoate content and the weight of the first polyhydroxyalkanoate is 5% to 95% of the combined weight of the first polyhydroxyalkanoate and the second polyhydroxyalkanoate (10) the first polyhydroxyalkanoate is a poly(3-hydroxybutyrate-co-3-hydroxyhexanoate) with a 3% to 15% 3-hydroxyhexanoate content and the second polyhydroxyalkanoate is a poly(3-hydroxybutyrate-co-4-hydroxybutyrate) with a 20-50% 4-hydroxybutyrate content and the weight of the first polyhydroxyalkanoate is 5% to 95% of the combined weight of the first polyhydroxyalkanoate and the second polyhydroxyalkanoate (11) the first polyhydroxyalkanoate is a poly(3-hydroxybutyrate-co-3-hydroxyhexanoate) with a 3% to 15% 3-hydroxyhexanoate content and the second polyhydroxyalkanoate is a poly(3-hydroxybutyrate-co-5-hydroxyvalerate) with a 20% to 50% 5-hydroxyvalerate and the weight of the first polyhydroxyalkanoate is 5% to 95% of the combined weight of the first polyhydroxyalkanoate and the second polyhydroxyalkanoate;
- or (12) the first polyhydroxyalkanoate is a poly(3-hydroxybutyrate-co-3-hydroxyhexanoate) with a 3% to 15% 3-hydroxyhexanoate content and the second polyhydroxyalkanoate is a poly(3-hydroxybutyrate-co-3-hydroxyhexanoate) having a 5%-50% 3-hydroxyhexanoate content and the weight of the first polyhydroxyalkanoate is 5% to 95% of the combined weight of the first polyhydroxyalkanoate and the second polyhydroxyalkanoate.
The composition of any of the preceding claims, wherein the polyester additive is PHA and the tear resistance of the recyclate blend is increased by 30-60%.
A method of preparing a recyclate blend composition, comprising
- melt blending a recyclate polymer and a polyester additive, using a single or twin screw extruder, two-roll mill, or Banbury mixer;
- wherein the recylate polymer is a recyclate poly (vinyl chloride) (PVC), recyclate nylon 6, recyclate polyoxymethylene (POM) or recyclate poly(methyl methacrylate), and the polyester additive comprises a PHA, an aromatic-alphatic polyester incorporating diols and diacids, a polybutylene-succinate or a polybutylene-succinate-adipate, and combinations thereof
A method comprising blending a recyclate polymer selected from the group consisting of recyclate poly (vinyl chloride) (PVC), recyclate nylon 6, recyclate polyoxymethylene (POM) and recyclate poly(methyl methacrylate), with a polyester additive in an amount suitable to form a blend having at least one of the following:
- a tensile modulus, tensile stress at yield, tensile strain at yield, tensile stress at break, tensile streass at break, energy at break, or tear, greater than the recyclate polymer;
- wherein the polyester additive is PHA, aromatic-alphatic polyesters incorporating diols and diacids, or polybutylene-succinate, polybutylene-succinate-adipate, and combinations thereof.
Dependencies are inferred from the claim text.