Sustainable injection molded articles

Abstract

A sustainable thermoplastic composition made by forming a mixture of virgin polypropylene and post-industrial-recycled material (PIR). The PIR may include a thermoplastic, elastomeric-polymer and a spunbond component. The mixture is melt-blended in an extruder. Extruded materials made from the mixture demonstrate little variance in the results of the IZOD Impact Test of materials containing 30 to 70 percent PIR, and a material containing 100 percent virgin polypropylene. In addition, the extruded materials containing 30 to 70 percent PIR demonstrate a substantially constant strain at yield, that strain at yield being substantially equal to that demonstrated by a material containing 100 percent virgin polypropylene.

1 . A method for forming a sustainable thermoplastic composition for injection molding, the method comprising:
 forming a mixture by supplying a virgin polymer and a post-industrial-recycled material (PIR) to a feed section of an extruder, wherein the PIR comprises a thermoplastic, elastomeric-polymer and a spunbond component; and   melt processing the mixture within the extruder to form the thermoplastic composition.   
     
     
         2 . The method of  claim 1  wherein the thermoplastic, elastomeric-polymer is a styrenic, thermoplastic, block-copolymer. 
     
     
         3 . The method of  claim 1  wherein the thermoplastic, elastomeric-polymer is selected from the group consisting of a polystyrene/poly(ethylenebutylene)/polystyrene) block copolymer; a linear tri-block copolymer based on styrene, ethylene/butylene and polystyrene; a styrene-butadiene-styrene block copolymer, thermoplastic polyurethane, thermoplastic polyolefin elastomers and a combination thereof. 
     
     
         4 . The method  claim 1  wherein the thermoplastic elastomeric-polymer has an average molecular weight of from about 65,000 g/mol to about 100,000 g/mol. 
     
     
         5 . The method of  claim 1  wherein the mixture comprises 5% to 90% PIR. 
     
     
         6 . The method of  claim 1  wherein the mixture comprises 20% to 80% PIR. 
     
     
         7 . The method of  claim 1  wherein the virgin polymers are selected from the group consisting of polyethylene, polypropylene, polystyrene, acrylonitrile-butadiene-styrene copolymers, polylactic acid, blends of polylactic acid and polyolefins and combinations thereof. 
     
     
         8 . The method of  claim 1  wherein the step of melt processing is performed at temperatures ranging from 160° C. to 240° C. 
     
     
         9 .- 20 . (canceled) 
     
     
         21 . The method of  claim 1 , wherein the PIR comprises a spun-bonded laminate comprising a thermoplastic polyolefin elastomer and a spunbonded fiber layer or an adhesive spun-bonded film laminate comprising a polyolefin film layer and a spunbonded fiber layer. 
     
     
         22 . The method of  claim 21 , wherein the spun-bonded laminate comprises a thermoplastic polyolefin elastomer and a spunbonded fiber layer. 
     
     
         23 . The method of  claim 21 , wherein the spun-bonded laminate comprises an adhesive spun-bonded film laminate comprising a polyolefin film layer and a spunbonded fiber layer. 
     
     
         24 . The method of  claim 1 , wherein the mixture is 30 to 70 parts by weight virgin polymer. 
     
     
         25 . The method of  claim 24 , wherein the PIR comprises the remaining parts by weight of the mixture. 
     
     
         26 . A method for injection molding an article, the method comprising:
 forming a mixture by supplying a virgin polymer and a post-industrial-recycled material (PIR) to a feed section of an extruder, wherein the PIR comprises a thermoplastic, elastomeric-polymer and a spunbond component;   melt processing the mixture within the extruder to form a thermoplastic composition; and   injection molding the thermoplastic composition to form the article.   
     
     
         27 . The method of  claim 26 , wherein the thermoplastic, elastomeric-polymer is selected from the group consisting of a polystyrene/poly(ethylenebutylene)/polystyrene) block copolymer; a linear tri-block copolymer based on styrene, ethylene/butylene and polystyrene; a styrene-butadiene-styrene block copolymer, thermoplastic polyurethane, thermoplastic polyolefin elastomers and a combination thereof. 
     
     
         28 . The method of  claim 26 , wherein the virgin polymers are selected from the group consisting of polyethylene, polypropylene, polystyrene, acrylonitrile-butadiene-styrene copolymers, polylactic acid, blends of polylactic acid and polyolefins and combinations thereof. 
     
     
         29 . The method of  claim 26 , wherein the PIR comprises a spun-bonded laminate comprising a thermoplastic polyolefin elastomer and a spunbonded fiber layer or an adhesive spun-bonded film laminate comprising a polyolefin film layer and a spunbonded fiber layer. 
     
     
         30 . The method of  claim 29 , wherein the spun-bonded laminate comprises a thermoplastic polyolefin elastomer and a spunbonded fiber layer. 
     
     
         31 . The method of  claim 26 , wherein the mixture is 30 to 70 parts by weight virgin polymer. 
     
     
         32 . The method of  claim 31 , wherein the PIR comprises the remaining parts by weight of the mixture.