# US 12,759,200 B2 · Method for manufacturing plastic molded article and plastic molded article > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 12,759,200 B2 - Document ID: US12759200B2 - Status: Granted - Kind: B2 - Application number: 18/588,244 - Filed: 2024-02-27 - Published: 2024-10-03 - Granted: 2026-10-13 - Earliest claimed: 2023-04-03 - Assignees: Toyoda Gosei Co., Ltd. - Applicants: Toyoda Gosei Co., Ltd. - Inventors: Shohei Yamamoto; Kazuki Takao; Hideto Maeda - Web page: https://patentgrep.com/patent/US12759200B2 ## CPC - B29C 45/0013: {using fillers dispersed in the moulding material, e.g. metal particles} - B29B 17/0404: {to powder} - B29K 2023/12: {PP, i.e. polypropylene} - B29K 2105/0032: {Pigments, colouring agents or opacifiyng agents} - B29K 2105/26: Scrap {or recycled material} - Y02W 30/62: Plastics recycling; Rubber recycling - Y10S 264/921: by injection molding material recycled from consumer used article or product - 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 (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00) - B29B: PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS - 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 - Y02W: CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT - Y10S: TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS ## Abstract A method for manufacturing a plastic molded article includes producing a granular waste material by finely pulverizing a waste material that includes a base made of a thermoplastic and a decorative layer provided on a surface of the base, producing a molten waste material by melting the granular waste material, injecting the molten waste material into a cavity of a mold and maintaining the molten waste material in a molten state in the cavity, and molding the plastic molded article by cooling the molten waste material that is maintained in the molten state. ## Claims ### Claim 1 A method for manufacturing a plastic molded article, the method comprising: producing a granular waste material by finely pulverizing a waste material that includes a base made of a thermoplastic and a decorative layer provided on a surface of the base; producing a molten waste material by melting the granular waste material; injecting the molten waste material into a cavity of a mold, wherein the mold has a molding surface for forming a decorative surface of the plastic molded article, and the mold is arranged such that the molding surface is positioned over the molten waste material in the cavity in a direction of gravity; maintaining the molten waste material in a molten state in the cavity for a predetermined time by maintaining a temperature in the cavity at a temperature at which solidification of the molten waste material can be avoided, wherein the predetermined time is a time sufficient for particles of the decorative layer contained in the molten waste material to precipitate in the cavity due to gravity; and molding the plastic molded article by cooling the molten waste material that is maintained in the molten state. ### Claim 2 (depends on 1) The manufacturing method according to claim 1, further comprising, prior to the melting of the granular waste material, producing a granular mixture by mixing the granular waste material and a granular virgin material that is made of the same thermoplastic as that of the base, wherein the melting of the granular waste material includes melting the granular mixture. ### Claim 3 (depends on 1) The manufacturing method according to claim 1, wherein during the maintaining of the molten waste material in the molten state, heating fluid flows through a heat medium passage in the mold. ### Claim 4 (depends on 1) The manufacturing method according to claim 1, wherein the predetermined time is 30 seconds to 60 seconds. ### Claim 5 A method for manufacturing a plastic molded article, the method comprising: producing a granular waste material by finely pulverizing a waste material including a molded body made of a thermoplastic colored with a pigment; producing a molten waste material by melting the granular waste material; injecting the molten waste material into a cavity of a mold, wherein the mold has a molding surface for forming a decorative surface of the plastic molded article, and the mold is arranged such that the molding surface is positioned over the molten waste material in the cavity in a direction of gravity; maintaining the molten waste material in a molten state in the cavity for a predetermined time by maintaining a temperature in the cavity at a temperature at which solidification of the molten waste material can be avoided, wherein the predetermined time is a time sufficient for particles of the pigment contained in the molten waste material to precipitate in the cavity due to gravity; and molding the plastic molded article by cooling the molten waste material that is maintained in the molten state. ### Claim 6 (depends on 5) The manufacturing method according to claim 5, further comprising, prior to the melting of the granular waste material, producing a granular mixture by mixing the granular waste material and a granular virgin material that is made of the same thermoplastic as that of the molded body and exhibits a color different from that of the waste material, wherein the melting of the granular waste material includes melting the granular mixture. ### Claim 7 (depends on 5) The manufacturing method according to claim 5, wherein during the maintaining of the molten waste material in the molten state, heating fluid flows through a heat medium passage in the mold. ### Claim 8 (depends on 5) The manufacturing method according to claim 5, wherein the predetermined time is 30 seconds to 60 seconds.