# US 2025/0326166 A1 · Co-injection molding of foam articles

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- Number: US 2025/0326166 A1
- Document ID: US20250326166A1
- Status: Published application
- Kind: A1
- Application number: 19/068,940
- Filed: 2025-03-03
- Published: 2025-10-23
- Earliest claimed: 2022-07-20
- Assignees: Trexel, Inc.
- Applicants: Trexel, Inc.
- Inventors: Levi A. Kishbaugh; Scott E. Ludwig
- Web page: https://patentgrep.com/patent/US20250326166A1

## CPC

- B29C 44/06: Making multilayered articles {(B29C44/0407 - B29C44/0492 take precedence)}
- B29C 44/04: consisting of at least two parts of chemically or physically different materials, e.g. having different densities
- B29C 44/0461: {by having different chemical compositions in different places, e.g. having different concentrations of foaming agent, feeding one composition after the other}
- B29C 44/42: using pressure difference, e.g. by injection or by vacuum
- B29K 2105/0032: {Pigments, colouring agents or opacifiyng agents}
- B29K 2105/26: Scrap {or recycled material}
- B29K 2995/0039: Amorphous
- B29K 2995/004: Semi-crystalline
- B29L 2009/00: Layered products
- 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)
- 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
- B29L: INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES

## Abstract

Articles comprising a skin layer comprising virgin polymer and a core layer comprising a recycled polymer, along with associated systems and methods, are generally provided.

## Claims

### Claim 1

A method of injection molding an article, comprising:
injecting a first fluid stream comprising a first polymeric material into a mold cavity;
injecting a second fluid stream comprising a second polymeric material and a blowing agent into the mold cavity to form a core; and
extracting the article from the mold cavity;
wherein the first polymeric material comprises a virgin polymer and the second polymeric material comprises a recycled polymer.

### Claim 2

An injection molded article, comprising:
a skin layer comprising a first polymeric material at least partially enclosing a foamed core comprising a second polymeric material,
wherein the first polymeric material comprises a virgin polymer and the second polymeric material comprises a recycled polymer.

### Claim 3 (depends on 2)

The article of claim 2, wherein the skin layer is integrally formed with the core.

### Claim 4 (depends on 1)

The article of claim 1, wherein the first polymeric material is a virgin polymer.

### Claim 5 (depends on 1)

The article of claim 1, wherein the first polymeric material and the second polymeric material comprise a same polymer.

### Claim 6 (depends on 1)

The article of claim 1, wherein the first polymeric material and the second polymeric material do not comprise a same polymer.

### Claim 7 (depends on 1)

The article of claim 1, wherein the first polymeric material comprises a colorant.

### Claim 8 (depends on 1)

The article of claim 1, wherein the article comprises greater than or equal to 25 wt % recycled polymer.

### Claim 9 (depends on 1)

The article of claim 1, wherein the wherein the first polymeric material comprises a polyolefin.

### Claim 10 (depends on 1)

The article of claim 1, wherein the second polymeric material comprises a polyolefin.

### Claim 11 (depends on 1)

The article of claim 1, wherein the first polymeric material and the second polymeric material are amorphous.

### Claim 12 (depends on 1)

The article of claim 1, wherein the first polymeric material and the second polymeric material are at least partially crystalline.

### Claim 13 (depends on 2)

The article of claims 2, wherein the foamed core has a density reduction of at least 3%.