Biodegradable, industrially compostable, and recyclable injection molded microcellular flexible foams
This document discloses a process for manufacturing recyclable injection molded microcellular foams for use in, footwear components, seating components, protective gear components, and watersport accessories. The process includes the steps of providing a thermoplastic polymer which comprises at least one monomer derived from depolymerized post-consumer plastic, inserting a fluid into a barrel of a molding apparatus. The fluid is introduced under temperature and pressure conditions to produce a super critical fluid. The process further includes mixing the thermoplastic polymer and super critical fluid so as to create a single phase solution, and injecting the single phase solution into a mold of an injection molding machine under gas counter pressure. The process further includes foaming the single phase solution by controlling the head and temperature conditions within the mold.
1. A method for manufacturing a recyclable flexible foam molded product comprising:
providing a thermoplastic polymer precursor comprising at least one monomer derived from depolymerized post-consumer plastic;
inserting a fluid into a barrel of a molding apparatus under temperature and pressure conditions to produce a super critical fluid;
mixing the thermoplastic polymer and the super critical fluid to create a single phase solution;
injecting the single phase solution into a mold of an injection molding machine wherein the mold is under gas counter pressure;
foaming the SCF-impregnated single phase solution by controlling heat and temperature conditions within the mold; and
recycling a flexible foam by depolymerizing the flexible foam into one or more monomers.
2. The method in accordance with claim 1 , wherein the thermoplastic polymer comprises at least 40% of the monomer derived from depolymerized post-consumer plastic.
3. The method in accordance with claim 2 , wherein the thermoplastic polymer comprises at least 60% of the monomer derived from depolymerized post-consumer plastic.
4. The method in accordance with claim 3 , wherein the thermoplastic polymer comprises 90% or more of the monomer derived from depolymerized post-consumer plastic.
5. The method in accordance with claim 1 , wherein the monomer comprises caprolactam.
6. The method in accordance with claim 1 , wherein the thermoplastic polymer comprises a polyamide based thermoplastic elastomer.
7. The method in accordance with claim 6 , wherein the thermoplastic polymer comprises a copolymer including at least one caprolactam monomer.
8. A method for manufacturing a recyclable flexible foam molded product comprising:
providing a thermoplastic polymer precursor comprising at least one caprolactam monomer derived from depolymerized post-consumer plastic;
inserting a fluid into a barrel of a molding apparatus under temperature and pressure conditions to produce a super critical fluid;
mixing the thermoplastic polymer and the super critical fluid to create a single phase solution;
injecting the single phase solution into a mold of an injection molding machine wherein the mold is under gas counter pressure;
foaming the SCF-impregnated single phase solution by controlling heat and temperature conditions within the mold.
9. The method in accordance with claim 8 , wherein the thermoplastic polymer comprises at least 40% of the monomer derived from depolymerized post-consumer plastic.
10. The method in accordance with claim 9 , wherein the thermoplastic polymer comprises at least 60% of the monomer derived from depolymerized post-consumer plastic.
11. The method in accordance with claim 10 , wherein the thermoplastic polymer comprises 90% or more of the monomer derived from depolymerized post-consumer plastic.
12. The method in accordance with claim 8 , further including the step of recycling a flexible foam by depolymerizing the flexible foam into one or more monomers.
13. The method in accordance with claim 12 , wherein the flexible foam is depolymerized into caprolactam.