Impact strength improvement of regrind

A process for forming a thermoformed article comprising:

• processing an article having at least one layer comprising virgin polyethylene and at least one layer comprising a material incompatible with polyethylene;
• removing trim from the article;
• collecting the trim to provide regrind comprising at least a portion of the virgin polyethylene and at least a portion of the material incompatible with polyethylene;
• and
• providing a regrind layer on the at least one layer comprising virgin polyethylene or the at least one layer comprising a material incompatible with polyethylene, the regrind layer comprising the regrind and at least one low density metallocene polyethylene in an amount sufficient to increase the impact strength of said article, as measured by the Gardner Impact Test at either room temperature or at −40° C.;
• and
• thermoforming the article from the at least one layer comprising virgin polyethylene, the at least one layer comprising a material incompatible with polyethylene, and the regrind layer.

In a thermoforming process comprising making an article and producing regrind, said article including:

• (A) a layer comprising polyethylene;
• (B) a layer comprising a material incompatible with polyethylene;
• and
• (C) a layer comprising regrind, the regrind comprising at least a portion of the polyethylene, and at least a portion of the material incompatible with polyethylene;
• the improvement comprising adding at least one low density metallocene polyethylene to said layer comprising the regrind;
• and
• thermoforming said article.

An article comprising a layer (A) comprising polyethylene, a layer (B) comprising a material incompatible with polyethylene;

• and a layer (C) comprising regrind and at least one low density metallocene polyethylene, the regrind comprising:
• at least a portion of the polyethylene layer (A);
• and
• at least a portion of the material incompatible with polyethylene in layer (B);
• wherein said layer (C) comprises greater than about 40 wt % of the entire article.

An article comprising a layer (A) comprising polyethylene, a layer (B) comprising a material incompatible with polyethylene, and a layer (C) comprising HDPE, at least one low density metallocene polyethylene and regrind, the regrind comprising:

• at least a portion of the polyethylene in layer (A);
• and
• at least a portion of the material incompatible with polyethylene in layer (B);
• wherein said layer (C) comprises greater than about 40 wt. % of said article.