EP4630218A1 - Procédé pour produire une feuille, procédé pour produire un granulat, une feuille et une installation de moulage de matière plastique - Google Patents

Procédé pour produire une feuille, procédé pour produire un granulat, une feuille et une installation de moulage de matière plastique

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Publication number
EP4630218A1
EP4630218A1 EP23832970.0A EP23832970A EP4630218A1 EP 4630218 A1 EP4630218 A1 EP 4630218A1 EP 23832970 A EP23832970 A EP 23832970A EP 4630218 A1 EP4630218 A1 EP 4630218A1
Authority
EP
European Patent Office
Prior art keywords
polymer
polymer blend
film
blend
process according
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
EP23832970.0A
Other languages
German (de)
English (en)
Inventor
Dr. Christoph LETTOWSKY
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Reifenhaeuser GmbH and Co KG Maschinenenfabrik
Original Assignee
Reifenhaeuser GmbH and Co KG Maschinenenfabrik
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Reifenhaeuser GmbH and Co KG Maschinenenfabrik filed Critical Reifenhaeuser GmbH and Co KG Maschinenenfabrik
Publication of EP4630218A1 publication Critical patent/EP4630218A1/fr
Pending legal-status Critical Current

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
    • B29C48/07—Flat, e.g. panels
    • B29C48/08—Flat, e.g. panels flexible, e.g. films
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/022—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the choice of material
    • B29C48/023—Extruding materials comprising incompatible ingredients
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
    • B29C48/05—Filamentary, e.g. strands
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
    • B29C48/09—Articles with cross-sections having partially or fully enclosed cavities, e.g. pipes or channels
    • B29C48/10—Articles with cross-sections having partially or fully enclosed cavities, e.g. pipes or channels flexible, e.g. blown foils
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/001—Combinations of extrusion moulding with other shaping operations
    • B29C48/0022—Combinations of extrusion moulding with other shaping operations combined with cutting
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2023/00—Use of polyalkenes or derivatives thereof as moulding material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2067/00—Use of polyesters or derivatives thereof, as moulding material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2077/00—Use of PA, i.e. polyamides, e.g. polyesteramides or derivatives thereof, as moulding material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2096/00—Use of specified macromolecular materials not provided for in a single one of main groups B29K2001/00 - B29K2095/00, as moulding material
    • B29K2096/02—Graft polymers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/0088—Blends of polymers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/04—Condition, form or state of moulded material or of the material to be shaped cellular or porous

Definitions

  • the invention relates to a method for producing a film with at least one layer with a polymer blend, comprising at least a first polymer and a second polymer, the invention further relates to a film with at least one layer with a polymer blend with at least a first polymer and a second polymer and furthermore to a plastic molding system for producing a film with at least one layer with a polymer blend, comprising at least a first polymer and a second polymer.
  • Plastics are polymers that consist of long chains of molecules. Unlike natural polymers such as cellulose or rubber, synthetic plastics can be precisely controlled in their properties and behavior. This makes them suitable for a wide range of applications in industry and everyday life.
  • plastics One of the most important properties of plastics is their malleability. By heating and then cooling them in a mold, they can be molded into almost any desired shape. The malleability of plastics makes it possible to create complex geometries and details that would be difficult or impossible with other materials.
  • plastics In addition to their moldability, plastics also have a variety of other properties that make them interesting for various applications. For example, they are lightweight, robust, durable, waterproof, chemical-resistant and electrically insulating. These properties make plastics the ideal material for packaging, protective covers, components and much more. The unparalleled prohibition of plastics since their availability is due to the very wide range of applications of this material and its diverse properties. Plastics are characterized by their very low density, mechanical properties that can be adjusted within wide limits, good processability and, last but not least, very good reprocessability as well as a wealth of other properties.
  • plastics are not biodegradable and can cause environmental pollution if not disposed of properly.
  • some plastics can release toxic substances over time that can be harmful to health. It is therefore important to use environmentally friendly and safe processes when manufacturing and disposing of plastic products. The reuse of plastics is also particularly relevant.
  • plastics are partly made from renewable raw materials and can be broken down by microorganisms, for example, without releasing toxic substances.
  • Plastics can be recycled in a number of ways, depending on their chemical composition and condition.
  • One option is mechanical recycling, where the plastics are broken down and processed into new products. This method is easiest for plastics that are still in good condition and can be easily broken into small pieces.
  • Another option is chemical recycling technology, where the plastics are broken down into their constituent parts and then processed into new plastic products. This method is suitable for plastics that are too dirty or damaged to be recycled by mechanical processes.
  • thermal recycling where the plastics are burned at high temperatures to generate energy. This method is best suited for plastics that can no longer be recycled.
  • Plastics are often made from blends of different polymers because these blends can improve certain properties that are important for the intended application. For example, the tensile strength or durability of a plastic can be increased by combining different polymers together. Blends of different polymers can also help reduce manufacturing costs by combining inexpensive polymers with more expensive ones. Another possibility why plastics are often blends of different polymers is that this makes them easier to process and mold, which is beneficial for industrial manufacturing of large quantities of plastic products.
  • plastics sometimes leads to problems with collection and recycling. For a long time, the plastics were therefore considered to be either not recyclable or only recyclable to a very limited extent.
  • the challenge in terms of recyclability is increased by the fact that plastic products often consist of different types of plastic, such as multi-layer films and/or film composites, so-called laminates. In such a case, the recyclates are a mixture of different types of plastic.
  • the recycling routes of material, raw material and energy recycling are selected.
  • Material recycling is the reprocessing of plastic waste into new products without significantly changing the molecular structure of the polymer molecules. This process is usually done by remelting the plastics. Material recycling is a process in which waste materials consisting of different materials are reused to produce new products. This Process is often used for plastics, paper, glass and metals. Unlike conventional recycling, where materials are broken down into their original components and then transformed into new products, mechanical recycling focuses on reusing materials in their existing state. This process can help conserve resources and reduce the environmental impact of waste.
  • Plastic regranulation is a process in which used or worn plastics are cut into small pieces and then reprocessed into small pellets. These pellets can then be reprocessed into new plastic products, enabling the reuse of plastics.
  • Regranulation is a form of mechanical recycling technology and is commonly used on plastics such as polyethylene, polypropylene and polystyrene. It is a cost-effective and environmentally friendly alternative to producing plastic products from crude oil.
  • the main advantage of granulation is that the quality of the regranulate can be influenced in a targeted manner, e.g. by targeted Adaptation of the extrusion process to the properties of the feedstock, and that the processor receives an easy-to-handle regranulate which can be processed essentially like new material.
  • the decisive factors as to whether material recycling is possible are the degree of contamination, the mixing with other plastics or other foreign substances such as printing inks or adhesives, and also the molecular structure or possible cross-linking of the polymer molecules.
  • the problem with mixing plastics is that most plastics are not compatible with each other.
  • plastic polymers belonging to the same polymer classes are miscible with each other and can be used in a blend.
  • polymers are polyethylene (PE), polypropylene (PP), and polystyrene (PS), all of which are polyolefins and are made from alkenes by chain polymerization.
  • PE polyethylene
  • PP polypropylene
  • PS polystyrene
  • These polymers are typically highly miscible with each other and can be made into a variety of plastic products.
  • polymers made from different chemical structures can also be used in a blend as long as they are carefully selected and compatible. It is important to note, however, that not all polymers are compatible with each other and some blends may cause undesirable properties. For this reason, it is important to plan and test carefully when using plastic blends to ensure that the desired properties are achieved.
  • miscibility refers to the compatibility of different thermoplastics.
  • Polymer blends or polyblends Mixtures of two or more different polymers are called polymer blends or polyblends.
  • a polymer blend is, alternatively or cumulatively, a mixture of two or more polymers that are bonded together by chemical or physical bonds. These blends are often used to improve certain properties of plastics by combining different polymers together. For example, the tensile strength or durability of a plastic can be increased by blending different polymers together. Polymer blends are also often used to reduce the manufacturing costs of plastic products by combining inexpensive polymers with more expensive ones.
  • the material properties of the polymers complement each other in such polymer blends; the properties of the blend depend on whether and to what extent the polymers involved in the mixture are compatible with each other, ie whether they mix completely with each other or whether they form separate phases.
  • the mixing processes required for this are described in Screw machines (single-screw extruders, twin-screw extruders, planetary roller extruders, etc.).
  • thermodynamic considerations Whether a two-component system is miscible or not can be deduced from thermodynamic considerations. Whether a two-component system is miscible or not can be deduced from thermodynamic considerations: A homogeneous mixture requires a free enthalpy of mixing AGm ⁇ 0. A polymer blend with a positive Gibbs energy of mixing (AGm > 0) is a heterogeneous mixture of incompatible polymers.
  • thermodynamic considerations in plastics refer to the application of the principles of thermodynamics to understand and describe the properties and behaviors of plastics.
  • thermodynamic considerations can be used to understand how the temperatures and states of plastics change under different conditions and how this affects their properties.
  • thermodynamic considerations can help understand the melting behavior of plastics and predict how their structure and properties change when heated and cooled.
  • compatible polymers Although the number of compatible polymers is limited, they have a certain significance. Their properties can be changed linearly with the proportion of homopolymers. The following mixtures of compatible polymers are of particular economic importance:
  • the monomer base is the basis from which polymers are made.
  • a monomer is a molecule that can combine with other monomers to form linked molecular chains. These linked molecular chains form the basis of polymers and determine their chemical properties and behavior.
  • the monomer base of a polymer can consist of a single monomer, which is called a homopolymer, or of several different monomers, which is called a copolymer.
  • the monomer base of a polymer has a decisive influence on its properties and behavior, and the choice of monomer base is an important factor in the development and manufacture of plastics.
  • Homopolymers are plastics that consist of a single polymer. This means that they are composed of identical monomers that do not differ in their chemical structure and properties. Homopolymers are produced, for example, by chain polymerization, in which a large number of monomers are linked to form a long, linked molecular chain. Properties of homopolymers are usually very uniform and can be easily predicted because they are made up of uniform molecules. Examples of homopolymers are polyethylene, polypropylene and polystyrene. In contrast to homopolymers, copolymers are plastics composed of two or more monomers.
  • mixtures of homopolymers with the same monomer base are mixtures of different polyethylenes, in particular mixtures of PE-LD and PE-LLD. This allows the difficult-to-process PE-LLD to be adapted to the existing machines, especially in the production of tubular film.
  • the mixture is usually produced during processing in the extrusion process.
  • PE-LLD Polyethylene Low Linear Density, a material made from polyethylene. It typically has a low linear density. It is often used in the manufacture of plastic packaging, films and bowls because it is lightweight, durable and inexpensive. The low linear density of PE-LLD results in a lower density of the material, resulting in lower mass and increased flexibility.
  • Rubber processing is the process by which raw rubber is made into products such as tires, rubber belts, and other rubber products. This process usually involves several steps, including foaming, kneading, and calendering the rubber. However, the exact steps and methods of rubber processing depend on the type of final product being produced.
  • An elastomer is a material that is very stretchable and elastic. It has the property of returning to its original shape after stretching or stress. Elastomers are often used in Industry uses it to make things like rubber, caoutchouc and rubber bands. Manufacturing tires and other rubber products that meet today's needs would not be possible without the ability to achieve the highest performance by blending different polymers.
  • incompatible polymers are very widely used. Most polymers are generally not miscible at the molecular level, in other words not compatible.
  • the blend consists of a continuous phase (also called the main phase) and a phase dispersed in it (also called the disperse phase or secondary phase).
  • a continuous phase also called the main phase
  • a phase dispersed in it also called the disperse phase or secondary phase.
  • two glass transition temperatures are recognizable in heterogeneous mixtures of two incompatible (immiscible) polymers.
  • Plastic waste from multi-component injection molded parts or films such as barrier films (e.g. PE/PA, PE/EVOH, PE/PA/EVOH, ...etc.) or laminates (e.g. PET/PE, PET/PP, PA/PE, etc.) etc. - if these are melted down again during recycling after use - are typical examples of heterogeneous mixtures of incompatible polymers.
  • the glass transition temperature of plastics is the temperature at which a plastic changes from a solid to a viscous state.
  • the glass transition temperatures of plastics can vary depending on the type of plastic and its composition. In general, however, the glass transition temperature of plastics is in a range of about 100 to 400 degrees Celsius. The glass transition temperature is much lower than 100 °C, particularly in semi-crystalline plastics, namely - 150 °C to + 400 °C.
  • the glass transition or softening temperature is the temperature at which a glass exhibits the greatest change in deformability.
  • Semi-crystalline plastics have both a glass transition temperature, below which the amorphous phase 'freezes' (accompanied by embrittlement), and a melting temperature at which the crystalline phase dissolves.
  • Glass transition temperature is an important factor in the manufacture of plastic products such as packaging, toys and electronic parts.
  • the structure of a heterogeneous mixture is characterized by the extent of the dispersed phase in the continuous phase.
  • the mechanical properties of such a heterogeneous mixture generally depend on the degree of dispersion of the dispersed phase and the adhesion between the phases in the solid state. In particular, it is desirable that the particles of the dispersed phase are as small as possible and evenly distributed in the homogeneous phase.
  • the division i.e. fineness, and also the distribution of the dispersed phase as well as the adhesion are poor.
  • processing machines i.e. the division and distribution of the dispersed phase, should be equipped with suitable mixing elements.
  • Extruders and/or mixing elements that generate not only a shear flow but also an extensional flow are particularly effective for generating fine particles.
  • modern kneading machines e.g. planetary roller extruders or twin-screw extruders
  • compatibilizers can be used to bind the phases together by grafting, i.e. to improve adhesion.
  • Compatibilizers can be copolymers, half of whose chains consist of monomers that are compatible with one of the two phases. These are incorporated into one of the two phases and ensure that the phases are anchored together. Both - good mixing and good adhesion - have a positive effect on the mechanical properties.
  • Compatibilizers are chemical additives used to improve the compatibility of different polymers in a mixture. They are often used when different polymers are mixed together to improve the properties and performance of the material. Compatibilizers can work in different ways, for example by improving the adhesion between the polymers or by influencing the rheological properties of the mixture. In each case, they serve to improve the properties of the mixture and make the material easier to process and use.
  • the rheological properties of a mixture refer to its behaviour and properties in the liquid state.
  • Rheology is the branch of physics that deals with the deformation and flow of materials, and the rheological properties of a mixture describe how it flows and deforms under certain conditions. These properties are important because they affect the processing and use of the mixture, for example when pouring, extruding or injecting materials.
  • the rheological properties of a mixture can be influenced by various factors, for example For example, the composition of the mixture, the temperature or the pressure.
  • a recyclate is a material that has been made from recycled plastics.
  • virgin plastics also known as new plastics, which are made from crude oil
  • recyclate is made from old plastics that have previously been collected.
  • melt flow index is a measure of how easily a plastic flows when melted. It is usually measured by a standardized test method in which a certain amount of the plastic is allowed to flow at a certain temperature and load. The higher the MFI value, the more easily the plastic flows when measured. The MFI is often used to assess the quality and processability of plastics.
  • PE-LD can be melted at just 160 °C and at the same time has a very wide temperature window
  • PA6/6.6-CoPolyamide and Polyamide 6 or even PET, for example, can only be processed above 245 °C or above 260 °C.
  • the different processing temperatures result from the different temperatures at which the different plastics become molten. These different temperatures are not untypical for heterogeneous mixtures and are even typical in the case of the plastic waste made up of several components mentioned above. A so-called DSC curve can make these different melting temperatures, or more precisely, melting ranges, visible.
  • a DSC curve is usually a curve produced by the DSC (Differential Scanning Calorimetry) method.
  • DSC is an analytical method used to determine heat capacity and thermal conductivity changes of materials. The curve shows the changes in the thermal conductivity or heat capacity of the material as a function of temperature. It is often used to study and compare the physiochemical properties of materials.
  • Contamination can be in the form of inorganic particles (e.g. aluminum or sand) or organic contamination (e.g. grease, water, filling material or paper) that cannot be removed by processing. have been removed. This results in markings, defects, incompatibilities or interactions with the polymer molecules, which then lead to a deterioration in quality.
  • inorganic particles e.g. aluminum or sand
  • organic contamination e.g. grease, water, filling material or paper
  • Degassing refers to the process of removing gases from a material.
  • degassing is an important step to improve the quality of the recycled material.
  • air bubbles and other gases can build up in the plastic, which can affect the quality and processability of the material.
  • Degassing removes these gases, resulting in a better final product.
  • degassing can be carried out in plastics recycling, for example by using vacuum techniques or by adding degassing agents.
  • Degassing offers the possibility, as with new goods, to remove low molecular weight components during the processing by extrusion, To remove gases or air from the melt.
  • the substances to be degassed are sometimes different due to the special composition of the recycling materials.
  • Removal of external contamination Volatile, mostly organic compounds that adhere to the plastics in the form of contamination are removed from the melt, e.g. fats, oils and sometimes printing inks or varnishes.
  • Degassing of solvents Solvents that have entered the material due to cleaning and separation stages used in the processing are removed. However, degassing also removes some substances that should remain in the material. These can be short-chain polymer components as well as added additives, in particular stabilizers, antioxidants, light stabilizers, plasticizers, etc.
  • the melt temperature is preferably set at the respective upper range of the temperature of the processed material, with a temperature range of about 90°C to 350°C, preferably between 110°C and 250°C, being preferred.
  • This targeted increase in the melt temperature at the upper range of the temperature spectrum of the processed material has proven to be particularly advantageous in order to ensure precise decomposition of the by-products.
  • the structural integrity of the actual polymer is ensured by the precise control of the melt temperature, which enables safe processing.
  • the escaping gases can be captured and subjected to special post-treatment, for example to minimize environmental impacts. This approach not only helps optimize production processes, but also emphasizes the environmentally conscious handling of emissions generated during decomposition.
  • melt filtration of plastics the material is passed through a filter element during melting to remove impurities and other solids from the plastic.
  • Plastic is passed through a filter element under pressure and at high temperatures, which filters out the solids from the plastic.
  • Melt filtration is an important step in plastic recycling as it helps to improve the quality of the recycled material and remove as many contaminants as possible. It is often used in combination with other techniques such as degassing to make the recycled material as pure as possible.
  • Filtration is generally understood to mean the separation of solid or liquid particles from fluids using a filter medium. In extrusion, filtration therefore has the task of separating all types of foreign particles, according to a selected filter fineness, and thus providing the purest possible melt.
  • melt filtration must meet the following requirements:
  • additives can help improve the quality of the recycled material by improving certain properties such as hardness, resistance to weathering or colour.
  • additives can help increase the processability of the recycled material by improving melting properties and making the material easier to process.
  • additives can also help increase the durability of the recycled material by delaying the aging of the material. Overall, additives help improve the performance of the recycled material and increase its value as a raw material.
  • the upgrading of plastic waste through additives can be divided into the incorporation of additives that are also used for new plastic products and the incorporation of additives that have been specifically developed for use in the reprocessing of plastic waste.
  • recycled plastics can be enhanced by, for example, mineral fillers, reinforcing fibers, color pigments, lubricants, plasticizers, etc.
  • the specific selection depends essentially on the intended use of the plastic.
  • mixed plastic waste usually has a grey, green or brownish colour. This means that even with the use of colour pigments, it is only possible to achieve colours that are difficult to define. While black, dark blue or brown colours are possible, lighter colours in particular cannot be achieved.
  • Stabilizers are chemical additives used in plastic manufacturing to improve the chemical stability of the plastic. They are often used to protect the plastic from damage caused by UV radiation, heat, and other external factors that can affect the chemical structure of the material. Stabilizers can also help to delay the aging of the plastic and extend its lifespan. Different types of stabilizers are usually used depending on what type of damage the plastic will potentially be exposed to and what properties it is intended to have.
  • Stabilizers have been specifically developed for this purpose to prevent molecular weight degradation and dark discoloration during reprocessing.
  • the polymer materials are damaged primarily by heat, atmospheric oxygen, light, moisture, high-energy radiation and microbial influences. Different stabilizers or combinations of these must therefore be used for the different influences and degradation mechanisms:
  • Antioxidants Protect polymers against oxidative degradation by oxygen, especially under the simultaneous influence of heat during processing.
  • Metal Protect polymers from accelerated thermo-oxidative
  • Degradation, deactivators which is triggered in some polymers by the presence of metals such as copper or iron.
  • Light stabilizers Protect polymers against light-induced degradation.
  • Biostabilizers Microorganisms can also attack and damage polymers, especially additives such as the plasticizers in PVC.
  • the way the stabilizers work is that they react more quickly with the oxygen or light present, for example, and thus protect the polymer itself from damage. However, this also means that the stabilizer is gradually used up and the polymer can still be damaged after it has been completely used up.
  • the dosage of the stabilizers is therefore crucial. This is generally between 0.05 and 5.0% by weight and is initially designed for a single use of the polymer. Re-stabilization is therefore necessary when reprocessing.
  • the dosage of the stabilizers is also determined by the polymer types, which differ considerably in terms of oxidation and light sensitivity.
  • optimal post-stabilization must take into account the previous damage, the existing residual stabilizer content, the reprocessing conditions and the subsequent application. Nevertheless, it must be noted that post-stabilization can only largely maintain the level of properties of the recyclates and cannot improve them beyond that.
  • compatibilizers Another important additive in the reprocessing of plastics are compatibilizers.
  • the aim of compatibilization is to improve the properties of a heterogeneous mixture of incompatible polymers.
  • Compatibilization strategies There are two different Compatibilization strategies: The first strategy consists in the addition of non-reactive compatibilizers (e.g. copolymers, nanoparticles or ionomers) to polymer blends to improve adhesion between the phases, hinder the growth of the phases (also called coalescence) and reduce the degree of dispersion.
  • non-reactive compatibilizers e.g. copolymers, nanoparticles or ionomers
  • Compatibilizers are mixed into the raw granulate in quantities of a few percent by weight.
  • non-reactive compatibilizers Addition of a further, e.g. third component, such as block or graft copolymers or ionomers whose components have improved compatibility with both incompatible components of the plastic mixture.
  • Block or graft copolymers are polymers that consist of two or more different monomer units that are linked together, with chains of another monomer type attached in a comb-like manner to a main chain formed from a monomer.
  • block or graft copolymers In contrast to linearly linked polymers, in which the monomer units are strung together in a single chain, block or graft copolymers have several sections with different monomer units. These sections can have different chemical properties and thus influence the properties of the overall polymer.
  • Block or graft copolymers are often used in the production of plastic mixtures to represent a binding partner between polymers that are not readily compatible with one another. The addition of nanoparticles as a non-reactive compatibilizer is also known.
  • Reactive compatibilization Modification of one or both incompatible components by grafting functional groups that have improved compatibility with the other component. Compatibilization, i.e. modification, occurs during blend production. This method is also called reactive compatibilization and the process is called reactive extrusion. Twin-screw extruders are particularly suitable for the tasks associated with reactive extrusion.
  • Adding a copolymer, i.e. a polymer with at least two different monomer units, to a heterogeneous mixture of incompatible polymers can reduce the interfacial tension between the phases, thus weakening phase separation and promoting the formation of a finely dispersed phase.
  • This process corresponds to the emulsification of immiscible liquids.
  • Block copolymers (diblock, triblock and multiblock copolymers) or graft copolymers are usually used.
  • a prerequisite for the use of copolymers as compatibilizers is that all polymers in the blend must interact with one of the segments (blocks) of the copolymer.
  • SEBS has been successfully used in PET/PE and PET/PP blends to improve the mechanical properties: The use of the compatibilizer led to a more homogeneous morphology, increased elongation at break and impact strength.
  • NP nanoparticles
  • the prerequisite for stabilizing the droplets - i.e. the dispersed phase - is that the NPs migrate to the interface between the matrix and the dispersed phase and have an equivalent attraction to the polymers present in the blend.
  • the NPs can have different shapes (spherical or platelet-shaped), chemical structures (silicon dioxide, calcium carbonate, organically modified montmorillonite) and sizes, and can have a surface coating (usually with organic molecules).
  • Ionomers are thermoplastic copolymers that have a "hanging" ionic group and thus have a relatively low ion concentration.
  • thermoplastics Due to the secondary valence forces (van der Waals forces, dipole-dipole interactions, hydrogen bonds) that are present in these thermoplastics, strong electrostatic forces exist between the polymer chains.
  • An example of an ionomer is ethylene-methacrylic acid copolymer.
  • This compatibilizer is used, among other things, to compatibilize a recycled blend of PE and PA and results in an increase in tensile strength, yield strength, elongation at break, impact strength and hardness compared to the polymer mixture without compatibilizer.
  • the intermolecular forces reduce the interfacial tension between the different phases.
  • thermoplastic namely EVA
  • compatibilizer ком ⁇ онент 1
  • the grafting of functional groups onto one or more components of a heterogeneous mixture of incompatible polymers to increase compatibility is referred to as reactive compatibilization.
  • the compatibilizers are often copolymers.
  • the homogenization of the incompatible polymers is promoted because, on the one hand, there are intermolecular forces of attraction between the copolymer and a component of the polymer mixture due to the polarity and, on the other hand, the copolymer forms a chemical bond with another component of the blend.
  • the more polar the compatibilizer the greater the intermolecular interactions between the phases.
  • the most commonly used compatibilizers in the plastics industry are maleic anhydride (MA)-grafted copolymers. These are reactive towards hydroxy (OH) and amino groups (NH2) and are therefore used in particular for mixed plastic wastes that have polymer chain ends with one of the two groups.
  • MA-grafted copolymers are used with a the blend partner forms a covalent bond, which results in an improvement of the mechanical properties.
  • anhydrides of unsaturated dicarboxylic acids can be used to introduce an anhydride group as a reactive group.
  • These are preferably produced using the so-called "grafting from” method of graft copolymerization.
  • the reactive compatibilization of a PE/PA mixture is possible, for example, with PE-g-MA, i.e. a polyethylene that has been grafted with maleic anhydride. Melting and compounding the thermoplastics with the compatibilizer results in the PE backbone of the copolymer building up van der Waals forces to form the polyethylene, and the anhydride group reacts with the amino group of the polyamide.
  • the dispersed phase is more uniform in its structure, the size of the particles decreases significantly, and the tensile properties increase.
  • Polyethylene grafted with maleic anhydride can also be used as a compatibilizer for PE/PET blends.
  • the anhydride group of the compatibilizer reacts chemically with the hydroxy group at the chain end of the PET and the PE portion of the PE-g-MA is miscible with the PE component of the polymer mixture as a result of physical bonding forces.
  • compatibilizers based on maleic anhydride are, for example, SEBS-g-MA for PE/PET or PE/PA blends and PP-g-MA for PE/PP systems or EVA-g-MA and EVB-g-MA for PE/PET or PE/PA blends.
  • maleic anhydride-grafted copolymers those with an unsaturated epoxy are known, such as with glycidyl methacrylate (GMA) as a reactive group.
  • GMA glycidyl methacrylate
  • acrylic acid (AA), ethylene-vinyl acetate copolymer (EVA) and maleimide (MI) are the usual functional groups that are either grafted onto polyolefins or copolymerized into compatibilizers.
  • Reactive extrusion can also be used to optimize compatibility through radical formation: the joint homogenization and processing of incompatible plastics with a radical starter in an extruder leads to the formation of macroradicals.
  • reactive polymers are able to form a covalent bond with the other blend partners and thus enable the formation of grafted or cross-linked copolymers.
  • the degree of cross-linking of the polymer mixture increases through the use of radical starters during mechanical recycling and thus increases compatibility.
  • the presence of radicals during the processing of plastics can also lead to oxidative degradation and chain degradation, which is why reactive extrusion must aim to maximize compatibilization and minimize chain scission.
  • Compatibilizers are used in the joint processing of plastic waste whose separation is either not technically possible or not economically viable, such as the reprocessing of coextruded plastic waste consisting of different incompatible polymers. These include multilayer film waste made of PE and PA, PE and EVOH or PE and PET or mixtures as well as laminates such as PE/PET, PE/PA, PP/PET, etc.
  • the joint reprocessing of plastic fractions from household waste (PE, EVA, ionomers, COC, PP, PET, PA, EVOH, PS, etc.) is also optimized by compatibilizers.
  • Coextruded plastics are plastics that consist of multiple layers that are manufactured simultaneously using an extrusion process. In this process, the different layers of plastic are passed through a die and extruded simultaneously, bonding them together. Coextruded plastics often have several properties that vary from layer to layer. For example, one layer of the plastic may have certain properties, such as hardness or resistance to weathering, while another layer may have other properties, such as flexibility or transparency. Coextruded plastics are often used in the manufacture of packaging, films, and other products where different properties are required.
  • PIR Post Industrial Recycling
  • This waste can take different forms, for example in the form of chips, dust, foams or incompletely manufactured products. It is often created by the processing of plastics, for example by extruding, punching, sawing or grinding the material.
  • Production or processing waste represents an important resource that can be reused or recycled in order to reduce the environmental impact of waste and conserve valuable resources.
  • Production or processing waste is generally largely uncontaminated and is therefore very suitable for material recycling. If it is pure, i.e. the waste is mainly made up of a basic raw material such as PE film, this waste is returned directly from the production plant into the material cycle. To be more precise, after processing, it is directly processed into new products, e.g. through the processing processes of extrusion, injection molding, blow molding, etc., whereby the processed materials are often mixed with new goods. In this case, it is referred to as in-house recycling.
  • the production or processing waste is a composite product, e.g. injection-molded parts made of several components or films made of several layers and/or film laminates made of different basic raw materials such as PE, EVA, ionomers, COC, PP, PET, PA, EVOH and others, but also printed films, etc.
  • the processing is initially carried out in a separate processing step.
  • This makes it possible to specifically influence the material properties of the Recycled materials can be used. This can be done by adding new material, additives, reinforcing or filler materials, by reactive extrusion or by degassing, and the end result is a recyclate that is very similar in appearance to the granulate of new material.
  • Post-consumer recycling refers to the recycling of plastics that have already been used by end users. Unlike PIR waste recycling, where plastics come directly from production, post-consumer recycling uses plastics that have been purchased and used by consumers and then disposed of as waste. These plastics can come from various sources, for example packaging, household appliances, furniture or other products. Post-consumer recycling is an important step in reducing plastic waste and conserving important resources.
  • PCR Post Consumer Recycling
  • An example of waste that is currently only recycled to a very limited extent is laminates made from PET and PE films. These are available in large quantities both as PIR goods and as PCR goods. At least one film of the laminate consists predominantly of PE raw materials with a thickness of 20 to 200 pm and at least one film consists predominantly of PET raw materials with a thickness of 8 to 20 pm. The PE proportion is always greater overall than the PET proportion in the laminate.
  • Another similar example is laminates made of PE from PET and PP, more precisely PET and CPP (cast PP) or PET and BO-PP (biaxially stretched PP). At least one film of the laminate consists predominantly of PP raw materials with a thickness of 10 to 200 pm and at least one film predominantly of PET raw materials with a thickness of 8 to 20
  • the PP content is generally always larger than the PET content in the laminate.
  • a film web can be printed over its entire surface or partially with solvent-based or solvent-free printing inks that are thermally stable or thermally unstable above approx. 200 °C.
  • solvent-based or solvent-free printing inks that are thermally stable or thermally unstable above approx. 200 °C.
  • Today, the standard for flexographic or gravure printing used in flexible packaging is often nitrocellulose-based printing inks, which form toxic gases during recycling in the extruder and lead to corrosion.
  • a film web can also be coated, in particular to increase the barrier effect of the laminate.
  • the barrier effect of plastics can be increased by various measures. Firstly, certain additives such as EVOH (ethylene vinyl alcohol copolymer) or PVDC (polyvinylidene chloride) can be used to improve the barrier effect of the plastic against oxygen, moisture, aromas and flavors. Secondly, the barrier effect can be increased by applying coatings to the plastic surface. Finally, the thickness of the plastic can also play a role, as thick plastic usually has a higher barrier effect than thin plastic. Overall, there are various ways in which the barrier effect of plastics can be improved, depending on the specific requirements and areas of application of the material.
  • EVOH ethylene vinyl alcohol copolymer
  • PVDC polyvinylidene chloride
  • Plastics are sometimes coated with a metallic layer to improve certain properties or add new functions.
  • a metallic layer can be used on plastic to improve its electrical conductivity to use it as an electrically conductive material.
  • a metallic layer can also help increase the plastic's resistance to weathering and corrosion by protecting it from damage caused by moisture, UV radiation or oxygen.
  • a metallic layer can also be used to give the plastic a to give a certain color or appearance, for example to create a gold, silver or metallic color.
  • the coating thickness is often less than 3 pm, usually 2 pm or less, sometimes only in the range of 3 to 50 nm ("met").
  • an adhesive layer e.g. EVA
  • EVA adhesive layer
  • laminates that can be used as input material are:
  • PE/PA PE/EVOH
  • PE/PA/EVOH PE/PA/EVOH
  • Such films are also known colloquially as barrier or high-barrier films. They are designed to minimize contact with certain environmental factors and thus extend the shelf life of packaged products.
  • the challenge with material recycling is that the polymers typically used (for example PE or PP in Combination with EVOH and/or PA etc.) are not compatible with each other, i.e. they cannot be mixed, i.e. they are not compatible.
  • Separating the individual components (PE, PP, PA, EVOH etc.) in the recycling process for targeted recovery is very complex and therefore unusual. Particularly when such films (barrier or high-barrier films) are printed, they can only be recycled to a limited extent - heavily diluted.
  • PET/PE laminates these films are available in large quantities both as PIR goods and as PCR goods.
  • non-pure waste can only be recycled on a small scale.
  • the proportion of waste in a new product is small; the waste is mixed with new goods.
  • the proportion of recyclate in the layer in which it is used is usually less than 30% by weight, very often less than 20% by weight.
  • the recyclate is usually processed, i.e. the waste is not directly processed to make a new product, but is first processed into granulate.
  • the problem with non-segregated waste is that it can contain plastics from waste streams that originate from household plastic collections, for example from recycling systems such as the yellow bag. Colloquially, these are referred to as medium or low quality PCR. These materials are commercially available in large quantities as granules, and a well-known example of this is the plastic recyclate from the Green Dot sold under the brand name "Systalen".
  • the composition of these recyclates varies and is not 100% known. In any case, there is a mixture of various plastics, even if these mainly consist of PE, i.e. more than 60%, preferably 80%, particularly preferably 90% and especially preferably 95% and more PE. It should be expressly mentioned that the composition of the mixture is not limited to plastic, but also, for example, contains a wide variety of contaminants; for example, but not limited to, contamination from printing ink.
  • waste such as transport packaging from the delivery area of supermarkets should be mentioned.
  • This can also generally be used, as these plastics are rarely contaminated and are also to be understood as recyclate in the context of this application. They usually come in the form of stretch film or hood film and thus offer a better starting point for high-quality material recycling.
  • twin-screw extruders enables more efficient processing of raw materials and opens up the possibility of using up to 100% recycled material.
  • Twin-screw extruders enable different plastics to be better homogenized and integrated into the production process.
  • the object of the invention is to provide such waste from the PIR and/or PCR sector for material recycling. To this end, it is proposed to use this as a blend in at least one layer of a new film.
  • the present invention is based on the object of providing an improvement or an alternative to the prior art.
  • the object is achieved by a method for producing a film with at least one layer with a polymer blend, comprising at least a first polymer and a second polymer, characterized in that at least two of the polymers involved are incompatible with each other and that the polymer blend is processed in an extruder.
  • the two or more layers may be fed from a single extruder or may be fed from several separate extruders.
  • the layer can be, for example, a single-layer film. However, it can also be a layer of a multi-layer film.
  • the layer distributions can be as follows: 25% - 50% - 25%.
  • the layer distribution is preferably 20% - 60% - 20%.
  • the layer distribution is particularly preferably 15% - 70% - 15%.
  • the layer distribution is particularly preferably 10% - 80% - 10%.
  • the preferred goal is to maximize the recyclate in the respective recyclate layer.
  • the different layer ratios enable precise adjustment depending on the specific requirements of the application. For example, a distribution of 25% - 50% - 25% enables even integration of the recyclate in the middle layer, while 10% - 80% - 10% enables focusing on a maximum amount of recyclate in the inner layer.
  • These flexible layer ratios preferably help to achieve the desired material properties while ensuring efficient use of recyclate in film production.
  • the layer distributions can be as follows: 10% - 20% - 40% - 20% - 10%.
  • the layer distribution is preferably 15% - 10% - 50% - 10% - 15%.
  • the layer distribution is particularly preferably 10% - 10% - 60% - 10% - 10%.
  • the layer distribution is particularly preferably 7.5% - 7.5% - 70% - 7.5% - 7.5%.
  • the actual proportions of the layer distribution depend largely on the desired properties of the film to be produced, in particular on the mechanical properties.
  • a targeted adjustment of these Properties can be achieved by controlling the proportions and/or the selection of materials, especially in the virgin material proportions of the outer layers and sub-outer layers (skin and subskin layers). By varying these parameters, certain mechanical properties such as strength, flexibility and durability can be influenced.
  • a higher concentration of virgin material in the outer layers enables improved strength and abrasion resistance, while a higher concentration of recycled material in the middle layer can help minimize the environmental footprint.
  • Precise adjustment of the layer composition makes it possible to produce tailor-made films with the desired performance characteristics for different applications. This flexibility in material selection and layer arrangement helps to adapt film production to specific requirements while promoting sustainable practices.
  • the polymer blend can of course also be present in an outer layer and/or sub-outer layer. This allows additional variability in film production, as the choice of layer in which the polymer blend is placed has specific effects on the final product properties.
  • the positioning of the polymer blend in the different layers makes it possible to integrate different functions into the film to meet the requirements of different applications.
  • This approach underlines the versatility of polymer blends in film production and the ability to tailor the material properties depending on the application and desired performance.
  • Another way to minimize odor is to post-treat the film with a plasma, which modifies the surface of the film.
  • This treatment can be carried out both offline and inline.
  • inline treatment can be carried out after the turning bar, preferably after the opening of the film tube or web, or before the winder.
  • offline treatment the film can be unwound after winding, treated and then wound again or used for further processing steps. This approach shows the variety of techniques available for minimizing odor in film production.
  • the middle layer or the layers containing the polymer blend can be foamed in a targeted manner.
  • This process can be achieved by adding chemical and/or physical blowing agents to the polymer blend.
  • the addition of these blowing agents enables controlled foaming, in which the degree of foam formation can be adjusted according to requirements.
  • This targeted foaming can reduce degassing, resulting in a more efficient and sustainable processing process.
  • the precise adjustment of the degree of foaming also opens up the possibility of dispensing with complete degassing, which not only optimizes the processing process but also saves resources. This innovative approach thus contributes to the further development of environmentally friendly processing technologies in the recycling sector.
  • the targeted foaming process makes it possible to encapsulate gases in the material.
  • closed cells are preferentially formed in the material, which contain the Enclose gases. This has the advantage that the gases are effectively encapsulated, which leads to a reduction in uncontrolled degassing, for example at the nozzle when the material exits the blow head.
  • the closed cells act like small barriers that enclose the gases inside the material and thus minimize release into the environment. This property not only helps to improve the material properties, but can also have a positive impact on the environmental balance by reducing the release of gaseous substances during processing and use of the material.
  • the film produced has properties comparable to those of conventional films and can therefore be further treated using the usual processes.
  • these films are stretchable, which means that they can be subsequently stretched to improve certain mechanical or optical properties.
  • the customization options are diverse. The versatility of these films therefore opens up various options for post-treatment and use in various industrial applications.
  • the films can be manufactured using various production processes, including air-cooled blown film extrusion, water-cooled blown film extrusion, cast film or sheet extrusion. This allows flexible adaptation of the film production to the specific requirements and areas of application.
  • the possible input materials that can be used as recyclate for the polymer blend are extremely versatile and consist, for example, of various types of printed and unprinted polyethylene films or polypropylene films. These materials, both PIR (Post Industrial Recyclate) and PCR (Post Consumer Recyclate), are used in a wide range of applications. Typical areas of application for recyclable films extend across various sectors, including packaging and transport, hygiene, agriculture, construction, industry, healthcare, clothing, leisure and outdoor, sanitary and heating installation, automotive or electrical industries. From the areas of packaging and transport, for example, PE films for garbage bags, carrier bags, food packaging, shrink and stretch films, hoods and liner films can be recycled. Another example is laminating film, which is used in combination with other materials.
  • PE films are used in the area of hygiene, especially in products such as diapers.
  • PE films play a crucial role, be it as greenhouse covers, mulch films, silage films or components of irrigation systems.
  • PE films are used as vapor barriers, seals for foundations and sewage pipes, as well as temporary construction films and geomembranes, which enable permanent barriers against the penetration of liquids or gases.
  • films in many different ways, be it in the form of bags, sacks for granules, powders or liquids, or for covering pallets and barrels.
  • films are used for medical packaging, bags and disposable products.
  • clothing industry for example, they are used in the production of protective covers.
  • Leisure and outdoor equipment benefits from films in tents, backpacks, waterproof bags and sleeping mats, for example.
  • Films also play a role in sanitary and heating installations, particularly for pipes.
  • the automotive industry uses films for car covers, seat protectors and interior fittings, for example.
  • films with antistatic properties protect electronic components, for example, while surface protection films protect against mechanical damage and often have a sticky surface.
  • Films that are preferably used as input material are also those that are used primarily in the packaging of foodstuffs or similar, so-called barrier films. These films are often used in further processing, for example as lidding films, in laminates or as Films that are deep-drawn are used. In addition to PE, these films often contain other polymers that are not compatible with PE; examples include polymers such as PA, CoPA, PET, EVHO, PVOH, etc. Today, the films usually have 5, 7, 9, 11 or more layers. However, barrier films are also known that consist of just three layers. The structure of the films can be symmetrical or asymmetrical.
  • the material blocks that ensure the barrier function as neighbors of the PE are characteristic, or more precisely the arrangement of the individual materials, or more precisely the layers: arrangements such as PE-HV-PA-HV-PE, PE-HV-EVOH-HV-PE, PE-HV-PA-EVOH- PA-HV-PE are particularly well known.
  • HV here stands for adhesion promoter.
  • Typical thicknesses range from 30 to 40 pm for lid films up to 300 pm and even 400 pm or more for thermoforming films or so-called tube laminate film.
  • Multilayer films with barrier materials are currently manufactured using state-of-the-art technology using both air-cooled blown film extrusion and water-cooled blown film extrusion as well as the multi-bubble process (double and triple bubble process) and also, for example, as flat film (cast film or sheet film).
  • Films that can be used as input material can be used as input material (for example PE film or PP film) and also barrier films can be unstretched or stretched.
  • stretched films are bi-axially stretched PE film (BO PE), bi-axially stretched PP film (BO PP), bi-axially stretched PA film (BO PA), mono-axially stretched P film (MDO PE) and mono-axially stretched PP film (MDO PP).
  • Another preferred input material for polymer blends are laminates. Such laminates can come from both PCR and PIR film applications.
  • any of the potential input materials mentioned can also be produced as a film with a recycled material, i.e. one or more or even all layers may contain a polymer blend.
  • Recycled material i.e. in particular a polymer blend
  • a polymer blend can be used in all known film applications; i.e. in principle, any of the films previously mentioned as potential input material can be produced with a recycled material, i.e. one or more or all layers of these films can have a polymer blend.
  • a polymer blend is usually a material that consists of two or more polymers mixed together.
  • the different polymers can have different properties, which can improve the overall material.
  • a polymer blend can consist of a hard polymer and an elastic polymer to obtain a material with high strength and good ductility.
  • Polymer blends are often used in the plastics industry to produce materials with specific properties. They can also be used to improve the performance of materials and increase their resistance to aging. Polymer blends are also used in other areas such as medical technology and the construction industry.
  • the polymer blend can be designed according to the definition described in the prior art.
  • a polymer is usually a large organic molecule compound made up of many smaller molecules called monomers.
  • Polymers come in many different forms and are widely used in nature and in synthetic chemistry. They are the basic building blocks of materials such as plastics, elastomers, and textile fibers.
  • thermoplastics There are two main classes of polymers: thermoplastics and thermosets.
  • Thermoplastics are polymers that become soft and malleable at elevated temperatures but solidify again at room temperature. They are often used to make plastics.
  • Thermosets are polymers that remain hard and dimensionally stable at elevated temperatures. They are often used to make paints and adhesives. In this case, thermoplastics are the preferred option.
  • the extruder preferably introduces a shear input into the polymer blend.
  • the shear input is measured in units such as Pascal (Pa) or bar and indicates how much pressure is required to drive a material through an extruder nozzle.
  • the shear load of an extruder depends on various factors, such as a nozzle shape, a nozzle size and a viscosity of the extruding material.
  • a high shear extruder can more easily process high viscosity and high strength materials and force them through the die.
  • the shear load of an extruder plays an important role in the manufacture of plastic products, especially in the extrusion of materials such as polymer blends and compounds.
  • a high shear load allows materials to be processed and formed with high quality and accuracy.
  • a low shear load on the other hand, can lead to contamination, warping and other quality problems.
  • the polymer blend has at least two glass transition temperatures.
  • the glass transition temperature is usually the temperature at which a material changes from a solid to a liquid state. Glass transition temperatures are specific temperatures, in which the material changes from an amorphous to a crystalline state.
  • the glass transition temperature of a material depends on various factors, such as its composition, structure and viscosity.
  • the glass transition temperature can be determined by measuring the heat capacity of the material, for example using differential scanning calorimetry (DSC).
  • the glass transition temperature plays an important role in the processing of materials, especially in the production of plastics.
  • a material with a low glass transition temperature can be processed at lower temperatures.
  • a material with a high glass transition temperature requires higher temperatures to melt.
  • each polymer has a single glass transition temperature.
  • the transition temperatures of the individual polymers are different from one another, so that their characteristic glass transition temperature can be detected in the polymer blend.
  • the glass transition temperature can also be a temperature range.
  • at least as many glass transition temperatures are to be expected in the polymer blend as there are different characteristic glass transition temperatures of the individual incompatible polymers.
  • the polymer blend has at least two ranges of characteristic melting temperatures.
  • the melting temperature also called melting temperature, is usually the temperature at which a material changes from a solid to a liquid state.
  • the melting temperature of a material depends on various factors, such as its composition, structure and viscosity.
  • the melting temperature can be determined by measuring the heat capacity of the material, for example using differential scanning calorimetry (DSC). It can also be determined by directly heating the material in a furnace or by applying laser radiation.
  • the melting temperature plays an important role in the processing of materials, especially in the production of plastics.
  • a material with a low melting temperature can be processed at lower temperatures.
  • a material with a high melting temperature requires higher temperatures to melt.
  • each polymer has a single melting temperature.
  • the melting temperatures of the individual polymers are different from each other, so that their characteristic melting temperature can be detected in the polymer blend.
  • the melting temperature can also be a temperature range. It is therefore preferable to have at least as many melting temperatures in the
  • Polymer blend as different characteristic melting temperatures of the individual incompatible polymers are to be expected.
  • the extruder has mixing elements which apply a shear input to the polymer blend and/or the first polymer and the second polymer in order to mix and/or homogenize the polymer blend and/or the first polymer and the second polymer.
  • the mixing elements are arranged, for example, at the end of the extruder to build up pressure to convey the polymer blend out of the extruder and out of the nozzle.
  • the mixing elements can also be mixing elements that are arranged at the beginning of the extruder or along the extruder section to mix the polymer blend or its precursors.
  • the polymer blend is usually described as two polymers that are incompatible with each other. However, the polymer blend can also be a mixture of more than two polymers.
  • it is a polymer blend of 2 to 5 polymers.
  • the extruder is designed as a single-screw extruder which applies a shear input to the polymer blend and/or the first polymer and the second polymer in order to mix and/or homogenize the polymer blend and/or the first polymer and the second polymer.
  • a single-screw extruder includes a barrel containing a spiral screw, also known as a flight or screw.
  • the screw is powered and drives the material through a nozzle of the extruder.
  • a single-screw extruder has many advantages over other types of extruders. It allows for even distribution of the material, high processing speed and high quality of the final products. It can also be easily adapted to the requirements of different materials and applications.
  • a single-screw extruder is often used in the plastics industry, especially in the production of plastic profiles, films and sheets.
  • the extruder is designed as a twin-screw extruder, which applies a shear input to the polymer blend and/or the first polymer and the second polymer in order to mix and/or homogenize the polymer blend and/or the first polymer and the second polymer.
  • a twin-screw extruder is similar in design to a single-screw extruder. However, it includes two screws that drive the material through the extruder's nozzle. The screws can, for example, rotate in opposite directions.
  • the extruder is preferably used to melt and homogenize the recycling material into a melt and has a melt stream.
  • the twin-screw extruder is a multi-screw extruder. In plastics technology, it is used to prepare and shape plastic melts. In this case, the recycled material or a material mixture with the recycled material is conveyed through a heated cylinder using two rotating, intermeshing screw shafts and is melted in the process.
  • Twin-screw extruders are usually divided into tangential or closely meshing co-rotation twin-screw extruders or tangential or closely meshing counter-rotation twin-screw extruders based on the axial distance between the two screw shafts and their direction of rotation.
  • the counter-rotation twin-screw extruder introduces less shear into the material to be extruded and therefore places less stress on it.
  • the counter-rotation twin-screw extruder is therefore preferably used when processing temperature-sensitive materials.
  • the co-rotation twin-screw extruder, in particular the closely meshing co-rotation twin-screw extruder is particularly preferred.
  • the twin-screw extruder has a particularly good mixing effect, which means that the plastic used can be processed.
  • recycling and/or mixing in additives is particularly advantageous with a twin-screw extruder.
  • the blown film system has a filter with at least one filter element for filtering the melt from an unfiltered side to a filtered side.
  • the filter serves as a dirt trap screen.
  • the filter is preferably a filter from the group of melt filters, extruder screens, filter discs and strainer screens.
  • the filter element can be single-layered, multi-layered or pleated.
  • the filter element can comprise a metal wire mesh, metal fiber fleece and/or sintered fabric laminate.
  • the filter is preferably arranged in the melt stream between the extruder and the ring nozzle.
  • the filter can also be part of the extruder.
  • the filter is arranged between the extruder and the ring nozzle melt pump.
  • the twin-screw extruder has at least one degassing unit, which enables extraction of impurities and contamination.
  • the degassing unit can be designed as a degassing zone as part of the extruder.
  • the degassing unit can be used to remove volatile components from the melt.
  • the filling level in the twin-screw extruder is below 100%, in particular it is preferred that the filling level is below 80%. Such a filling level is preferred because otherwise the melt would be pushed into degassing nozzles and would escape from the degassing unit.
  • the twin-screw extruder has at least one degassing unit which is designed as an atmospheric degassing unit.
  • the volatile components can be released from the degassing unit without applying a negative pressure.
  • the twin-screw extruder has at least one degassing unit which is designed as a vacuum degassing unit.
  • a vacuum is applied to the degassing unit.
  • the vacuum can be created by a vacuum pump.
  • the degassing unit in particular the vacuum degassing unit, has a means for collecting the volatile components, preferably in the form of condensate.
  • entraining agents can be used.
  • the use of entraining agents is an effective method for increasing the degassing performance when processing recyclate.
  • Entraining agents are special substances that can be introduced into the polymer blend of the recyclate to promote the release of gases during the processing process in the extruder. These substances influence the degassing properties of the recyclate, usually by reducing the surface tension and thus promoting the formation of gas bubbles. This leads to improved diffusion of gases from the recyclate and enables more efficient degassing.
  • the selection of the appropriate entraining agent depends on the specific requirements of the process and the desired material properties. The targeted integration of entraining agents into the manufacturing process helps to optimize the quality of the end product while making the processing more efficient.
  • the extruder has a recycling material feed with a stuffing screw.
  • the stuffing screw allows the recycling material to be fed to the extruder particularly evenly.
  • the recycling material feed preferably has a hopper in which the stuffing screw is arranged.
  • the stuffing screw is preferably driven by a drive that is independent of the extruder.
  • the blown film system has at least two pressure sensors for detecting pressures within the guide for the melt stream, preferably in the guide for the melt stream at the extruder and in front of the ring nozzle.
  • the pressure sensors are designed to detect the melt pressure in the melt stream during operation of the blown film system.
  • the blown film system has at least two pressure sensors for detecting the melt pressure in the melt flow at the extruder and in front of the ring die.
  • the first pressure sensor is preferably arranged directly on the extruder or beyond the extruder.
  • the second pressure sensor is preferably arranged directly in front of the ring die or on the ring die.
  • the second pressure sensor is arranged in front of the ring die melt pump.
  • the extruder and/or the ring die melt pump and/or the recycling material feed can preferably be controlled depending on the melt pressure in the melt flow which is fed from the first and/or second Pressure sensor on the extruder and/or in front of the ring nozzle can be regulated.
  • the blown film system has two additional pressure sensors for detecting the melt pressure in the melt flow before and after the filter.
  • These additional pressure sensors are therefore pressure sensors that are present in addition to the pressure sensors mentioned above.
  • These additional pressure sensors can be installed directly before and after the filter. However, it is preferred that the additional pressure sensors are positioned immediately before the filter and immediately before the ring nozzle. In this design, the second pressure sensor is preferably positioned immediately after the filter.
  • the filter has a cleaning device which renews the filter element continuously and/or discontinuously.
  • the term "renewed” is understood to mean both cleaning a filter element and the insertion of a new filter element which was not previously used as a filter element or was cleaned before being used again.
  • the insertion can be done manually or, preferably, automatically.
  • the extruder is designed as a twin-screw extruder with screws running in the same direction, also called co-rotating. In this embodiment, the two screws run in the same direction.
  • the extruder is designed as a planetary roller extruder, which applies a shear input to the polymer blend and/or the first polymer and the second polymer in order to mix and/or homogenize the polymer blend and/or the first polymer and the second polymer.
  • a planetary roller extruder usually comprises a driven central spindle on which several individual planetary spindles, the number of which can be varied, roll.
  • the rotating planetary spindles are usually also guided over an internally toothed bushing (roller cylinder). This movement drives the material through the nozzle of the extruder.
  • additives are added to the polymer blend and/or the first polymer and the second polymer to improve miscibility.
  • Additives are typically materials or additives that are added to another material to improve or change its properties. Additives are often used in the plastics industry to modify materials such as polymers, elastomers, polymer blends and compounds and to adapt their properties to the requirements of their final products.
  • Additives can have various functions, such as improving strength, hardness, elasticity, resistance to chemicals and temperatures, resistance to aging and color. They can also be used to make materials easier to process or to change their optical properties.
  • odorants can be added. These additives serve to mask or neutralize odors that could arise during the recycling process.
  • the selection of odorants is preferably aimed at ensuring a pleasant and acceptable environment during processing without affecting the quality of the end product.
  • Stabilizers such as antioxidants
  • antioxidants can be integrated into the manufacturing process of polymer blends. These stabilizers help to reduce the formation of defects and particles in the material.
  • the addition of antioxidants preferentially slows down the degradation of the polymer due to oxidative stress, which can improve the stability and quality of the polymer blend. This helps to maintain the mechanical and chemical properties of the material and thus optimize the performance of the recycled product.
  • MFI Melt Flow Index
  • the viscosities of the polymer blend components can be regulated, for example, by adding new material to the manufacturing process.
  • higher-viscosity materials can be mixed in to improve bubble stability during production on a blown film line.
  • materials with an MFI value of 1, preferably 0.7, particularly preferably 0.3 or less are used. Precise adjustment of the viscosity helps to optimize the processing properties of the polymer blend and increase the quality of the films produced, particularly with regard to bubble stability and end product quality.
  • compatibilizers are added to the polymer blend and/or the first polymer and the second polymer to improve miscibility.
  • the compatibilizers are preferably constructed according to the compatibilizers described in the prior art.
  • the compatibilizer is a polymer, a block or graft copolymer.
  • a block polymer is usually a polymer made up of two or more different monomers, usually arranged at regular intervals in the polymer chain.
  • Block polymers are usually made by combining two or more polymers that have different properties.
  • Block polymers depend primarily on the type and arrangement of the monomers and the length of the block segments.
  • Block polymers can have hard and soft regions and can occur in different states of aggregation, such as amorphous and crystalline regions.
  • Block polymers are often used in the plastics industry to produce materials with specific properties. They can also be used to improve the performance of materials and increase their resistance to aging.
  • block polymers require special processes, such as polymer-polymer coupling or block polymerization.
  • the properties of block polymers can be precisely controlled by the choice of monomers and block lengths in order to obtain materials with the desired properties.
  • Block polymers can be used as additives in polymer blends and compounds to improve the properties of these materials.
  • Graft copolymerization is usually a technique for producing polymers whose main chain forms the starting point for further chains of a different monomer type. This creates a copolymer whose main chain is usually followed in a comb-like manner by chains of a further monomer type. This provides another way of developing plastics with new, defined properties.
  • a graft polymer is preferably a material that consists of polymers and is produced by a grafting process. In the grafting process, for example, two or more polymers are joined together to create a new material with improved properties. This can be used in plastics technology to create materials with specific properties such as high strength or low water absorption.
  • the compatibilizer is an EVA polymer or an ionomer polymer.
  • the EVA polymer is preferably ethylene-vinyl acetate copolymer, which is usually made from ethylene and vinyl acetate. It is preferably a flexible material. EVA preferably leads to increased flexibility, elasticity and chemical resistance.
  • Ionomer polymers are preferably polymers that contain ionic bonds and are therefore electrically conductive. They are usually produced by combining polymers and metal ions and are usually characterized by their high strength, chemical resistance and electrical conductivity.
  • a compound with a reactive group is grafted onto the first polymer and/or the second polymer in order to improve miscibility.
  • the reactive group is an epoxy group, which is preferably introduced by reaction of the polymer with glycidyl methacrylate (GMA).
  • GMA glycidyl methacrylate
  • the epoxy group usually refers to a structure consisting of a carbon atom bonded to two oxygen atoms. This structure is often found in epoxy compounds made by the reaction of phenols and epoxy oils. Epoxy groups are usually very reactive and can react with various other chemicals such as amines or polyols to create new compounds with different properties.
  • Glycidyl methacrylate (GMA) is a monomer that is produced, for example, by the reaction of methacrylic acid with epichlorohydrin. It belongs to the class of epoxidized methacrylates and is an important starting material in the production of epoxy resins and other epoxy compounds. GMA is usually characterized by its high reactivity and its ability to improve the properties of polymers, for example by increasing their chemical resistance and/or hardness. It is preferably used in various areas of the plastics industry, for example in the production of coatings.
  • the reactive group is an anhydride group, which is preferably introduced by reaction of the polymer with maleic anhydride (MA).
  • the anhydride group usually refers to a special structure consisting of a carbon atom connected to two oxygen atoms. It is formed, for example, when an acid is deprived of its water molecules and can be created by heating or by treating it with solvents.
  • Anhydrides are usually very reactive compounds and can react with various chemicals such as alcohols or amines to form new compounds. They are often used in the plastics industry, for example as reaction accelerators.
  • MA Maleic anhydride
  • MA is an anhydride that is produced, for example, by heating maleic acid. It belongs to the class of dicarboxylic acids and is usually characterized by its high reactivity and its ability to improve the properties of polymers. MA is often used in the plastics industry, for example as a reaction accelerator in the production of polyester resins or as a crosslinking agent in the production of polyurethanes. It can also be used as a plasticizer in PVC plastics.
  • the polymer blend predominantly comprises two types of plastic.
  • the two types of plastic preferentially make up the largest amount of the material.
  • the first polymer is a polyolefin or a polymer blend of several different polyolefins.
  • Polyolefins are a class of polymers that are usually made from olefins. Olefins are usually organic compounds that contain a double bond between two carbon atoms. Examples of olefins are ethylene and propylene. Polyolefins are usually made by polymerizing olefins and are usually characterized by their high strength, chemical resistance and weather resistance.
  • the first polymer is a polyethylene or a polymer blend of several different polyethylenes.
  • PE Polyethylene
  • ethylene is a polymer that is usually made from ethylene. It belongs to the class of polyolefins and is one of the most commonly produced polymers in the world. PE is usually characterized by its high strength, chemical resistance and weather resistance. It is used, for example, in the production of films, foams, pipes and cable insulation.
  • the first polymer is a polypropylene or a polymer blend of several different polypropylenes.
  • Polypropylene is a thermoplastic usually produced by chain polymerization of propene. It belongs to the group of polyolefins, is semi-crystalline and non-polar. Its properties are similar to polyethylene, but it is generally somewhat harder and more heat-resistant.
  • the second and a possibly present third polymer is a barrier polymer.
  • the barrier polymer is from the group with EVOH, PA, PET, PE, PP and PVC. Strictly speaking, PET, PE and PP are not classic barrier polymers.
  • a barrier polymer is a type of polymer that typically provides a barrier to the movement of molecules or ions through it.
  • Barrier polymers are used in many applications, such as food packaging. They are often made from materials such as polyethylene, polypropylene or polyethylene terephthalate (PET), which are known for their durability and chemical and moisture resistance.
  • PET polyethylene terephthalate
  • the specific properties of a barrier polymer depend on its chemical structure and the type of molecules it is designed to block.
  • EVOH, PA, PET, PE, PP and PVC are each different types of plastic.
  • EVOH, PA, PET, PE, PP and PVC are each different types of plastic.
  • EVOH or ethylene vinyl alcohol
  • EVOH is a copolymer often used as a barrier material in packaging applications. It is known for its high oxygen and moisture barrier properties, making it useful for maintaining the freshness of food and other perishable products.
  • PA or polyamide
  • nylon is a type of polymer also known as nylon. It is typically a strong, durable material used in a variety of applications.
  • PET polyethylene terephthalate
  • PET polyethylene terephthalate
  • PE polyethylene
  • PP polypropylene
  • polypropylene is a plastic that is commonly used in a variety of applications, such as food containers, packaging materials, and automotive parts. It is commonly known for its durability, light weight, and resistance to chemicals and heat.
  • PVC polyvinyl chloride
  • the second polymer is an EVOH or a polymer blend of several different EVOHs.
  • the second polymer is a PA, preferably a PA6/6.6 copolyamide or polyamide 6, or a polymer blend of several PAs.
  • the PA content in the polymer blend is less than 50 wt.%, preferably the PA content is less than 35 wt.% and particularly preferably the PA content is less than 25 wt.%.
  • New material can also be added to the polymer blend.
  • polyolefin preferably polyethylene
  • the amount of new material can vary depending on the quality of the input material of the polymer blend or depending on the proportion of foreign bodies in the polymer blend.
  • new goods consist mainly of polyethylene.
  • the second polymer is a PET or a polymer blend of several different PETs.
  • the PET content in the polymer blend is less than 2.5 to 50 wt.%, preferably the PET content in the polymer blend is 3.5 to 37.5 wt.% and particularly preferably the PET content in the polymer blend is 4.5 to 25 wt.%.
  • the first polymer and/or the second polymer is subjected to a preparation step before processing in the extruder.
  • processing steps usually refer to the various processes used to produce polymers. These steps include, for example, the pretreatment and processing of raw materials, polymerization (the joining of smaller molecules into larger polymers), shaping of the polymers and subsequent post-treatment of the plastics formed.
  • the aim of the processing steps is usually to improve the properties and quality of the polymers and to make them suitable for their intended applications.
  • the first polymer and/or the second polymer are in the form of granules before processing in the extruder.
  • the first polymer and/or the second polymer may have been subjected to a targeted processing step in order to have it already present in the form of a blend in granulate form.
  • This upstream processing makes it possible to combine the different polymer components in a homogeneous mixture that is present as granulate.
  • the polymers are not present individually, but preferably already as a harmonized blend mixture.
  • These prefabricated granulates offer numerous advantages in further processing, as they enable improved handling and dosing during the manufacturing process. Targeted processing in the form of granulates thus not only facilitates the processing step, but can also lead to help increase efficiency and consistency in the production of recycled polymers.
  • the advantage of the first polymer and/or the second polymer already being present as granules is that this enables better degassing.
  • Another advantage is, for example, that gentler melting is possible.
  • the granules enable gentler melting during the process. This leads to improved temperature control and enables precise adjustment of the melt temperature.
  • the term "gentle melting" refers to a process in which heating to a molten phase takes place with a controlled and gradual increase in temperature. This takes place without abrupt or rapid increases in temperatures in order to minimize potential thermal stress. The aim is to retain the structure and properties of the material as much as possible during the melting process while ensuring the desired processing properties.
  • polymer granules therefore helps to minimize potential thermal stress and enables efficient homogenization of the melt. This aspect not only promotes optimal processing of the materials, but also helps to maintain the structural integrity of the film produced, which is particularly important with regard to quality standards and material life.
  • the upstream processing of the polymer blend can be carried out, for example, in a single-screw extruder or a twin-screw extruder. These extruders are used to melt, mix and homogenize the polymer blend.
  • a single-screw extruder consists of a single rotating screw, while a twin-screw extruder has two parallel rotating screws. Both types of extruder offer the possibility of efficiently processing the polymer blend and shaping it into the desired shape.
  • processing can be carried out with or without degassing.
  • gases that are released during the melting process arise or, more precisely, escape, i.e. pass into the gas phase - e.g. low molecular weight impurities, are removed from the material. This is relevant to improve the quality of the end product and minimize possible defects.
  • the decision to degas during processing depends on the specific requirements of the recycling process and the desired material properties.
  • the polymer blend, or at least one of its polymers can be subjected to pre-filtration during the processing step. This can be advantageous in order to reduce the amount of machinery required. This pre-filtration makes it possible to set up the machine more simply, to use cheaper filters and/or to change filters less frequently. In this case, for example, a screen changer with backwashing can be dispensed with. This pre-filtration preferably contributes to fewer specks being formed in the end product, as larger contaminants are removed before the upstream processing step.
  • Another advantage of the pre-manufactured granules is that it may be possible to dispense with the use of a second melt pump. This not only optimizes the efficiency of the recycling process, but can also lead to cost savings and an overall simplified plant configuration.
  • Another advantage of the processing step is that the polymer blend can be degassed during processing. This not only helps to increase the overall degassing performance, but also enables the reduction of odor nuisances during the actual processing.
  • Two-stage degassing i.e. during processing and during the actual processing, can enable an increase in the proportion of recycled material.
  • Granulate production with degassing during processing thus functions as a type of pre-degassing.
  • the processing step also enables the processing of fluff into granules. This processing step makes it easier to mix a wide variety of material flows and batch fluctuations can be more easily compensated. It is possible to mix smaller material flows and thus increase the versatility of recyclate processing.
  • the granules resulting from the processing step melt more evenly and more quickly than fluff, which is added to the process without a processing step.
  • the use of granulate from the preparation step offers advantages during processing in the twin-screw extruder. This enables gentler processing of the polymer blend, can extend the degassing area of the screw and help to reduce possible temperature peaks. This in turn preferably leads to fewer specks, reduces unmelted parts in the polymer blend and improves the melting behavior.
  • the granulate from the preparation step preferably helps to enable more uniform process control, which can be reflected in stable extrusion pressures and uniform temperatures throughout the entire processing process.
  • the first polymer and/or the second polymer are processed directly in the extruder without a preparation step prior to processing.
  • polymers in the form of granules.
  • the polymers can, for example, be in the form of shredded packaging parts from the two sources mentioned above.
  • the raw materials for the production of polymer blends from shredded packaging parts can be extremely diverse and come in different forms. This can, for example, be in the form of Flakes or fluff or even powder, which are produced by shredding or in raw material form.
  • the raw materials can be in various states, including web material, mixtures of web material and/or granules. These materials can contain both virgin material and already recycled plastics (PCR - Post Consumer Recyclate, PIR - Post Industrial Recyclate).
  • the raw materials can already be processed.
  • the raw materials can also be, for example, shredded goods, granulate mixtures, powder, fillers or even empty but already used or unused packaging.
  • This variety of possible raw materials offers a flexible basis for the production of polymer blends and makes it possible to specifically influence the properties of the end product.
  • plastic waste can be processed sustainably and in a resource-efficient manner.
  • the first polymer and/or the second polymer are present as production or processing waste.
  • Additives from the group of process materials, new goods and other materials can be added to the production or processing waste.
  • the other materials can be any other polymers.
  • the first polymer and/or the second polymer is present as a laminate.
  • the laminate preferably comprises two to five layers, but the laminate can also be more than five-layer laminates. For example, eleven-layer laminates.
  • the laminate can be added as a glued-together film, but also individual films, e.g. the PET film before it is glued together with a PE film.
  • the laminate can be a precursor to a laminate.
  • Precursors to a laminate are, for example, still separate layers that are not yet connected to one another.
  • the first polymer and/or the second polymer is present as a laminate, preferably at least two layers of the laminate are joined together with a polyurethane-based adhesive with a layer thickness of 1 to 4 gsm.
  • Polyurethane-based adhesives are usually adhesives that are made on the basis of polyurethane.
  • Polyurethane is a synthetic polymer that is usually made from isocyanates and polyols. These adhesives usually have a high adhesive strength and are therefore often suitable for bonding different materials. They are usually elastic and can therefore be applied to materials with different expansion coefficients without the adhesive bond breaking.
  • Polyurethane-based adhesives are common in various forms, such as spray adhesives, liquid adhesives or adhesive pads.
  • the first polymer and/or the second polymer is present as a laminate. At least two layers of the laminate are preferably joined together with an acrylic resin dispersion/emulsion adhesive.
  • the adhesive preferably has a layer thickness of 1 to 4 gsm.
  • Acrylic resin dispersion or acrylic resin emulsion adhesives are usually adhesives that are made from acrylic resin.
  • the acrylic resin is usually dissolved in water or another solvent in the form of of small particles to obtain a homogeneous dispersion or emulsion.
  • These adhesives usually have very strong adhesion and good ageing resistance.
  • the first polymer and/or the second polymer is present as a laminate.
  • at least one layer of the laminate is printed.
  • a film web can be fully or partially printed.
  • the printing inks can be solvent-based or solvent-free.
  • the printing inks are preferably thermally stable or thermally unstable above 200 °C.
  • the object is achieved by a method for producing a film by extrusion with at least one layer with a polymer blend, which is processed according to the manner described above.
  • the object is achieved by a method for producing a film by means of blown film extrusion, flat film extrusion in the cast process or flat film extrusion in the sheet process, with at least one layer with a polymer blend, characterized in that the polymer blend is processed according to one of claims 1 to 33.
  • the object is achieved by a method for producing a granulate for producing a film by means of extrusion, characterized in that the granulate has a polymer blend with at least a first polymer and a second polymer, and that at least two of the polymers involved are incompatible with one another.
  • the polymer blend has at least two glass transition temperatures.
  • the glass transition temperatures are already defined and described above.
  • the polymer blend has at least two ranges of characteristic melting temperatures.
  • the melting temperatures are already defined and described above.
  • the object is achieved by a film having at least one layer with a polymer blend with at least a first polymer and a second polymer, characterized in that at least two of the polymers involved are incompatible with one another.
  • the polymer blend has at least two glass transition temperatures.
  • the glass transition temperatures are already defined and described above.
  • the polymer blend has at least two melting temperatures.
  • the melting temperatures are already defined and described above.
  • the film is manufactured according to the manner described.
  • the task solves a
  • Plastics molding plant in particular blown film plant, flat film plant for cast processes or flat film plant for sheet processes, for producing a film with at least one layer with a polymer blend, comprising at least a first polymer and a second polymer, thereby characterized in that at least two of the polymers involved are incompatible with each other.
  • the polymer blend has at least two glass transition temperatures.
  • the glass transition temperatures are already defined and described above.
  • the polymer blend has at least two melting temperatures.
  • the melting temperatures are already defined and described above.
  • the film is produced according to one of the described types.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Processing And Handling Of Plastics And Other Materials For Molding In General (AREA)
  • Extrusion Moulding Of Plastics Or The Like (AREA)

Abstract

L'invention concerne un procédé pour produire une feuille comprenant au moins une couche comportant un mélange de polymères comprenant au moins un premier polymère et un deuxième polymère, caractérisé en ce qu'au moins deux des polymères concernés ne sont pas compatibles entre eux et en ce que le mélange de polymères est traité dans une extrudeuse. Cette invention concerne également une feuille comprenant au moins une couche comportant un mélange de polymères comprenant au moins un premier polymère et un deuxième polymère, caractérisé en ce qu'au moins deux des polymères concernés ne sont pas compatibles entre eux. L'invention concerne en outre une installation de moulage de matière plastique, en particulier une installation de fabrication de feuilles soufflées ou une installation de fabrication de feuilles plates, pour produire une feuille comprenant au moins une couche comportant un mélange de polymères, présentant au moins un premier polymère et un deuxième polymère, caractérisée en ce qu'au moins deux des polymères concernés ne sont pas compatibles entre eux.
EP23832970.0A 2022-12-10 2023-12-11 Procédé pour produire une feuille, procédé pour produire un granulat, une feuille et une installation de moulage de matière plastique Pending EP4630218A1 (fr)

Applications Claiming Priority (2)

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DE102022132893 2022-12-10
PCT/EP2023/085175 WO2024121435A1 (fr) 2022-12-10 2023-12-11 Procédé pour produire une feuille, procédé pour produire un granulat, une feuille et une installation de moulage de matière plastique

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EP4630218A1 true EP4630218A1 (fr) 2025-10-15

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CN (1) CN120379818A (fr)
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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4410482A (en) * 1979-03-06 1983-10-18 E. I. Du Pont De Nemours & Co. Process for making laminar articles of polyolefin and a condensation polymer
JPH1148312A (ja) * 1997-08-04 1999-02-23 Mitsubishi Kagaku Polyester Film Kk 非相溶性重合体含有ポリエステルフィルムの製造方法
US20130154151A1 (en) * 2011-12-20 2013-06-20 Kimberly-Clark Worldwide, Inc. Method for Forming a Thermoplastic Composition that Contains a Renewable Biopolymer
BR112020024397B1 (pt) * 2018-05-30 2024-02-20 Amcor Flexibles North America, Inc Filmes para embalagem com teor de poliamida reciclada
WO2021231248A1 (fr) * 2020-05-12 2021-11-18 Cryovac, Llc Procédé de fabrication d'un mélange compatibilisé à partir d'un mélange de matériau polymère

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