Recycled and renewable polymeric compositions for computer casings

Abstract

Polymeric compositions, methods of making the compositions, and composites, such as computer cases containing the compositions, are described. The polymeric compositions can contain: 20 to 50 weight percent post-consumer mechanically recycled polycarbonate; 10 to 50 weight percent renewably sourced polycarbonate; 10 to 30 weight percent filler containing carbon fibers, wherein at least a portion of the carbon fibers are obtained from an industrial post-use recycling source; and 5 to 15 weight percent flame retardant, wherein the polymeric composition has a total recycled and renewable content of 50 to 90 weight percent.

Description

[0001] Cross-reference to related applications

[0002] This application claims priority to U.S. non-provisional patent application serial number 17 / 082,975, filed on October 28, 2020, the entire contents of which are incorporated herein by reference. Background of the Invention

[0004] A. Technical Field

[0005] This invention generally relates to polymeric compositions having a high recyclability and renewability content while possessing sufficient mechanical strength for use in articles of manufacture. For example, these polymeric compositions can be used in the computer industry (e.g., chassis) and can also be applied to more sustainable products (e.g., desktop computers, laptop computers, or mobile computers).

[0006] B. Related Technical Description

[0007] Polycarbonate is used in electronic and electrical devices such as computers, laptops, mobile phones, personal computers, e-readers, and personal tablets due to its light weight and good mechanical properties. However, some commonly used polycarbonates (such as bisphenol A (BPA) polycarbonate) are non-biodegradable and can cause various environmental problems if not recycled, such as landfilling, increased use of natural resources and energy. Therefore, efforts have been made to increase the recycling rate of products using polycarbonate. Traditional recycling methods include mechanical recycling. Mechanical recycling typically involves collecting used products or fragments containing a target polymer (e.g., polycarbonate-based plastics), washing the used products or fragments as needed, melting the used products or fragments into raw materials containing the target polymer, and reusing the raw materials to produce new products. A problem with mechanical recycling is that the mechanical properties (e.g., tensile strength, tensile modulus, etc.) of the recycled plastic (e.g., polycarbonate) are weakened. This weakening of mechanical properties can be caused by the mechanical recycling process itself (e.g., energy input during the melting process can cause polymer chain breakage and produce weaker polymers). Therefore, as the amount of mechanically recycled polymer increases, the mechanical properties of the product can be weakened (e.g., reduced ductility). This significantly limits the amount of recycled material that can be used in products (e.g., various parts of electronic and electrical devices).

[0008] A typical solution to counteract the diminished mechanical properties of mechanically recycled polymers is to use additives and introduce other materials into the polymer composition. This approach can increase the costs associated with the polymer composition, reduce its sustainability, and / or introduce caustic or environmentally unfriendly materials. Summary of the Invention

[0009] A discovery has been made that provides a solution to at least some of the aforementioned problems. In one aspect of the invention, the solution may include supplementing a polymeric composition comprising a mechanically recycled polymer (e.g., mechanically recycled polycarbonate) with additional recycled components and / or components made from renewable materials. This can produce articles with a high total content of recycled materials without harmfully compromising the mechanical strength of the resulting articles (e.g., chassis for desktop computers, laptops, or mobile devices). In one aspect of the invention, it has been found that compositions containing specific amounts of post-consumer mechanically recycled polycarbonate, renewable-source polycarbonate, recycled carbon fiber, and flame retardants can have excellent mechanical properties and a high recycling and renewable content. Therefore, articles made from such compositions are more sustainable and / or less harmful to the environment.

[0010] One aspect of the present invention relates to a polymeric resin composition. The polymeric composition may contain post-consumer mechanically recycled polycarbonate, renewable-source polycarbonate, a carbon fiber-containing filler, and optionally a flame retardant. In some aspects, the polymeric composition may contain 20% to 50% by weight of post-consumer mechanically recycled polycarbonate, 10% to 50% by weight of renewable-source polycarbonate, 10% to 30% by weight of carbon fiber-containing filler, and 5% to 15% by weight of flame retardant. The post-consumer mechanically recycled polycarbonate may contain at least a portion of mechanically recycled polycarbonate from post-consumer waste. In some aspects, the post-consumer mechanically recycled polycarbonate may have a recycling content of 80% to 100% by weight, or 90% to 100% by weight, or 95% to 100% by weight, or 98% to 100% by weight, or 99% to 100% by weight, or about 100% by weight. The renewable-source polycarbonate may be produced at least partially from renewable raw materials. The renewable feedstock may be oilseed oil, sugar, castor meal, and / or CO2, such as waste CO2. In some particular aspects, the renewable feedstock may be oilseed oil derived from wood pulp. Renewable source polycarbonate may include carbon atoms from the renewable feedstock. In some aspects, the renewable content of the renewable source polycarbonate may be from 13% to 65% by weight. In some aspects, at least a portion of the carbon in the renewable source polycarbonate may be derived from the renewable feedstock. In some aspects, at least 70%, 80%, 90%, 95%, or 100% of the carbon in the renewable source polycarbonate may be derived from the renewable feedstock. In some aspects, at least a portion of the oxygen and / or hydrogen in the renewable source polycarbonate may be obtained from a non-renewable source.

[0011] In some aspects, the polymeric resin composition may contain a polycarbonate polymer that is a non-recycled polymer (e.g., virgin polycarbonate) and obtained from a non-renewable source. In some aspects, the polymeric resin composition may contain less than 5% by weight, less than 2% by weight, less than 1% by weight, or less than 0.1% by weight of polycarbonate, or contain no polycarbonate, or substantially no polycarbonate, wherein the polycarbonate is a non-recycled and non-renewable polycarbonate.

[0012] At least a portion of the carbon fiber can be obtained from recycled industrial waste. In some aspects, the carbon fiber may have a recycled content of 10% to 30% by weight. The carbon fiber may contain standard modulus, intermediate modulus, and / or high-strength carbon fibers. In some aspects, the optional flame retardant may be obtained at least partially from a renewable source. In some aspects, the renewable content of the flame retardant may be 20% to 50% by weight. In some aspects, the flame retardant may be a non-halogenated flame retardant. In some aspects, the flame retardant may be a non-halogenated phosphorus-containing flame retardant obtained from bio-based chemicals. In some aspects, the flame retardant may be bisphenol A-diphosphate obtained from bio-based chemicals. In some aspects, the polymeric composition may also contain one or more additives selected from the group consisting of: pigments, plasticizers, antioxidants, UV stabilizers, heat stabilizers, dye enhancers, lubricants, release agents, nucleating agents, flowability improvers, antistatic agents, compatibilizers, or anti-dripping agents, or any combination thereof. In some aspects, the one or more additives may be pigments and plasticizers. In some aspects, the polymeric composition may contain 20% to 50% by weight of post-consumer mechanically recycled polycarbonate, 10% to 50% by weight of renewable source polycarbonate, 10% to 30% by weight of filler, 5% to 15% by weight of flame retardant, 0.1% to 3% by weight of pigment, and 0% to 5% by weight of plasticizer. The polymeric composition may have a total recycled and renewable content of 50% to 90% by weight. The polymeric compositions of the present invention may have any one, any combination of, or all of the following properties: a density of 1 g / cc to 1.4 g / cc, 1.25 g / cc to 1.35 g / cc, or 1.28 g / cc to 1.3 g / cc as measured according to ASTM D792 at 23°C; a tensile modulus equal to or greater than 17000 MPa, or 17000 MPa to 22000 MPa, or 17000 MPa to 20000 MPa as measured according to ISO 527-1 or ISO 527-2 at 5 mm / min at 23°C; a tensile breaking strength equal to or greater than 155 MPa, or 155 MPa to 190 MPa, or 155 MPa to 170 MPa as measured according to ISO 527-1 or ISO 527-2 at 5 mm / min at 23°C; and a tensile breaking strength equal to or greater than 155 MPa, or 155 MPa to 190 MPa, or 155 MPa to 170 MPa as measured according to ISO 527-1 or ISO 527-2 at 23°C; and a tensile breaking strength equal to or greater than 155 MPa, or 155 MPa to 190 MPa, or 155 MPa to 170 MPa as measured according to ISO 527-1 or ISO 527-2 at 23°C. 527-2 Elongation at break of ≥1.1%, ≥1.3%, or ≥1.4% as measured at 1 mm / min; and flexural modulus at 23°C equal to or greater than 15500 MPa, or from 15500 MPa to 19000 MPa, or from 15500 MPa to 17500 MPa, as measured at a test speed of 2 mm / min according to ISO 178. In some aspects, the composition may be contained in a film, layer, or sheet.In some aspects, the polymeric composition can be a composition for extrusion molding, blow molding, injection molding, rotational molding, compression molding, 3D printing, and / or thermoforming. In some aspects, the polymeric composition can be included in an article of manufacture. In some aspects, the article of manufacture can be a computer part. The computer can be a desktop computer, laptop computer, notebook computer, mobile phone, tablet computer, calculator, or the like. In some aspects, the article of manufacture can be a computer chassis or chassis part, such as a desktop computer chassis or chassis part or a laptop computer chassis or chassis part.

[0013] In some aspects, the polymeric resin compositions of the present invention can have a higher elongation at break at 23°C, as measured according to ASTM D638 at a test speed of 5 mm / min, than that of substantially the same reference composition containing post-consumer mechanically recycled polycarbonate as an alternative to renewable source polycarbonate. As used herein, “substantially the same reference composition” is a composition comprising the same components and the same amounts of components as the example composition, except that the reference composition does not include the listed components (e.g., the components are omitted). In the case of removing a component, the weight percent of the removed component is added to the main polymer in the composition. Thus, if the example composition comprises 35 wt% post-consumer mechanically recycled polycarbonate, 35 wt% renewable source polycarbonate, 20 wt% filler, and 10 wt% flame retardant, the substantially the same reference composition containing post-consumer mechanically recycled polycarbonate as an alternative to renewable source polycarbonate comprises 70 wt% post-consumer mechanically recycled polycarbonate, 20 wt% filler, and 10 wt% flame retardant. The recovery content of the reference composition may be the same as the total recovery and recyclable content of the example composition.

[0014] One aspect of the invention relates to a computer chassis containing the polymeric composition described herein. The computer chassis can be used for desktop computers, laptop computers, notebook computers, or mobile devices (e.g., mobile phones, tablet computers, calculators, or the like). Certain aspects relate to desktop computer chassis, laptop computer chassis, or tablet computer chassis containing the polymeric composition described herein. In some aspects, the recycled and recyclable content of the computer chassis can be at least 70%. The recyclable and / or recyclable materials of the computer chassis can contain plastics and / or carbon fibers.

[0015] One aspect of the present invention relates to a method of manufacturing a computer chassis described herein. The method may include forming and / or obtaining a polymeric composition described herein, and forming at least a portion of the computer chassis with the polymeric composition.

[0016] Other embodiments of the invention are discussed throughout this application. Any embodiment discussed with respect to one aspect of the invention is also applicable to other aspects of the invention, and vice versa. Each embodiment described herein is to be understood as an embodiment of the invention applicable to other aspects of the invention. It is contemplated that any embodiment discussed herein can be implemented with respect to any method or composition of the invention, and vice versa. Furthermore, the compositions of the invention can be used to implement the methods of the invention.

[0017] The following includes definitions of various terms and phrases used throughout this specification.

[0018] As used herein, the recycling content of a material refers to the percentage by weight of material obtained from, made from, and / or recovered from waste. Unless otherwise stated, waste can be post-industrial or post-consumer waste. Post-consumer waste of material is waste generated by a consumer containing a substrate of said material. Post-industrial waste is waste generated during the production of a product that has not yet been used in the consumer market.

[0019] As used herein, the renewable content of a material refers to the percentage by weight of the material obtained from or made from a bio-based renewable material. Unless otherwise stated, bio-based materials can include materials derived from any life form, such as plants, animals, fungi, protists, prokaryotes, microorganisms, algae, bacteria, yeasts, and / or molds. Bio-based materials can be obtained from natural or genetically engineered species. Non-limiting examples of bio-based renewable materials include oilseed floats, sugar, castor meal, and / or CO2, such as waste CO2.

[0020] As used herein, the gross recycled and renewable content of a material refers to the percentage by weight of material obtained from, made from, and / or recycled from waste, and the percentage by weight of material obtained from or made from bio-based renewable materials. For example, for 100 gm of material, if 10 gm is obtained from a recycled source and 10 gm is obtained from a renewable source, the gross recycled and renewable content of the material is 20 gm.

[0021] As used in this article, a computer chassis refers to an outer casing, a shell component used for a computer and / or computer parts, such as a central processing unit (CPU), a monitor, a monitor's display, input devices (e.g., a keyboard, mouse, and / or mouse pad), storage units (e.g., solid-state drives, hard disk drives, graphics processing units, random access memory), sound cards, speakers, microphones, webcams, and / or motherboards.

[0022] As will be understood by those skilled in the art, the terms “about” or “approximately” are defined as close to. In one non-limiting embodiment, the term is defined as within 10%, preferably within 5%, more preferably within 1%, and most preferably within 0.5%.

[0023] The terms "weight %", "volume %", or "molar %" refer to the percentage by weight, volume, or mole of a component, respectively, based on the total weight, total volume, or total moles of the material comprising the composition. In a non-limiting example, 10 grams of a component in 100 grams of material is 10% by weight of the component. The term "ppm" refers to parts per million (ppm) based on the total weight of the material comprising the component.

[0024] The term “substantially” and its variations are defined as including the range within 10%, within 5%, within 1%, or within 0.5%.

[0025] The terms “suppress” or “reduce” or “prevent” or “avoid” or any variations thereof, when used in the claims and / or specification, include any measurable reduction or complete suppression for achieving the desired result.

[0026] The term “effective” as used in this specification and / or claims means sufficient to achieve the desired, anticipated or desired result.

[0027] The use of the word "a" in any of the combining terms "comprising," "including," "containing," or "having" in the claims or specification may mean "one," but it is also consistent with the meaning of "one or more," "at least one," and "one or more."

[0028] The phrase “and / or” means both or both. For illustration, A, B and / or C includes: only A, only B, only C, combinations of A and B, combinations of A and C, combinations of B and C, or combinations of A, B and C. In other words, “and / or” is used as an inclusive or inclusive term.

[0029] The words “comprising” (and any form of inclusion, such as “comprise” and “comprises”), “having” (and any form of having, such as “have” and “has”), “including” (and any form of inclusion, such as “includes” and “include”), or “containing” (and any form of containing, such as “contains” and “contain”) are inclusive or open-ended and do not exclude additional unmentioned elements or method steps.

[0030] The polymeric compositions of the present invention may “comprising” specific ingredients, components, compositions, etc. disclosed throughout the specification, “consistently composed of” or “composed of” specific ingredients, components, compositions, etc. In one aspect of the invention, and referring to the conjunctions “consist(s) essentially of” or “consisting essentially of”, the essential and novel characteristics of the invention may include polymeric compositions having (1) high recyclability and renewability content and / or (2) high impact strength properties.

[0031] All disclosures mentioned herein are incorporated herein by reference to disclose and describe various methods and / or materials, and the disclosures are mentioned in conjunction with the methods and / or materials.

[0032] Other objects, features, and advantages of the present invention will become apparent from the following detailed description and examples. However, it should be understood that the detailed description and examples, while indicating a given embodiment of the invention, are given by way of illustration only and are not intended to be limiting. Furthermore, variations and modifications within the spirit and scope of the invention are expected to be understood by those skilled in the art from its detailed description. In other embodiments, features from a particular embodiment may be combined with features from other embodiments. For example, a feature from one embodiment may be combined with features from any of the other embodiments. In other embodiments, additional features may be added to the particular embodiments described herein. Attached Figure Description

[0033] Those skilled in the art will appreciate the advantages of the invention upon referring to the accompanying drawings and the following detailed description. While the invention is subject to various modifications and alternatives, specific embodiments are shown in the drawings by way of example. The drawings may not be to scale.

[0034] Figure 1 The diagram illustrates various polymer recycling methods.

[0035] Figure 2 This is a schematic diagram of a laptop computer according to an embodiment of the present invention. A) shows a front view of the laptop computer, B) shows a side view of the laptop computer, C) is a schematic diagram of the bottom panel of the laptop computer, and D) is a schematic diagram of the top panel of the laptop computer.

[0036] Figure 3 This is a schematic diagram of a desktop computer according to an embodiment of the present invention.

[0037] Figure 4This is a schematic diagram of a desktop computer or mobile phone according to an embodiment of the present invention. Detailed Implementation

[0038] A discovery has been made that provides solutions to at least some of a number of problems that may be associated with increasing the recycled content of polycarbonate containing polymeric compositions without harmfully compromising the usability of the composition in articles (e.g., enclosures for electronic devices). In one aspect of the invention, the discovery may comprise a polymeric composition containing 20% ​​to 50% by weight of post-consumer mechanically recycled polycarbonate, 10% to 50% by weight of renewable-source polycarbonate, 10% to 30% by weight of carbon fiber-containing filler, and 5% to 15% by weight of flame retardant, wherein the polymeric composition may have a total recycled and renewable content of 50% to 90% by weight. The mechanical properties of such compositions are sufficient for use in articles that may have extensive applications and / or may be prone to disposal (e.g., enclosures for electronic devices). Significantly, the high recycled and renewable content of the compositions of the present invention can result in more sustainable or “green” articles without compromising cost and / or mechanical strength.

[0039] refer to Figure 1 This document provides a schematic diagram of polymer plastic recycling methods. Petroleum-derived polymers (e.g., polycarbonate) can be used to form various articles that become waste after use (e.g., consumer products, such as computer cases). Polymers are primarily recovered from waste through mechanical recycling. In mechanical recycling, waste is recovered through a physical process in which the polymer chains are not reduced to the monomer units that form the polymer. More precisely, mechanical recycling typically involves collecting waste containing a target polymer (e.g., polycarbonate-based plastic), cleaning the waste as needed, melting the waste into raw materials containing the target polymer, and reusing the raw materials to produce new articles. However, the mechanical properties of mechanically recycled polymers are weakened by the heat used in melting. Heat can weaken the polymer molecular chains. Polymers can also be recovered from waste through chemical recycling. In chemical recycling, the polymer from waste depolymerizes into monomer units, and the monomer units are polymerized again to form the chemically recycled polymer. Furthermore, polymers formed from bio-based chemicals can also be used to form articles with increased recyclability. In certain aspects of the invention, the recyclability and renewability of the polymeric composition are increased by supplementing the mechanically recycled polycarbonate content with renewable-source polycarbonate, recycled carbon fibers, and optionally renewable-source flame retardants, while maintaining the desired mechanical properties of the composition. As illustrated in the examples in a non-limiting manner, the polymeric compositions of the present invention can have higher tensile elongation at break compared to comparative compositions that do not contain renewable-source polycarbonate.

[0040] These and other non-limiting aspects of the invention will be discussed in more detail in the following subsections.

[0041] A. Polymer composition

[0042] The polymeric composition may contain: i) post-consumer mechanically recycled polycarbonate from 20% to 50% by weight, or at least any one of the following, equal to any one of the following, or between any two of the following: 20% by weight, 25% by weight, 30% by weight, 35% by weight, 40% by weight, 45% by weight, and 50% by weight; ii) renewable source polycarbonate from 10% to 50% by weight, or at least any one of the following, equal to any one of the following, or between any two of the following: 10% by weight, 15% by weight, 20% by weight, 25% by weight, 30% by weight, 35% by weight, 40% by weight, 45% by weight, and 50% by weight. % and 50 wt%; iii) the following carbon fiber-containing fillers: 10 wt% to 30 wt%, or at least any one of the following, equal to any one of the following, or between any two of the following: 10 wt%, 15 wt%, 20 wt%, 25 wt%, and 30 wt%, wherein at least a portion of the carbon fiber is available from an industrial post-use recycled source; and iv) the following flame retardants: 5 wt% to 15 wt%, or at least any one of the following, equal to any one of the following, or between any two of the following: 5 wt%, 7 wt%, 9 wt%, 10 wt%, 11 wt%, 13 wt%, and 15 wt%.

[0043] In some aspects, the polymeric composition may also contain one or more additives selected from pigments, plasticizers, antioxidants, UV stabilizers, heat stabilizers, dye enhancers, lubricants, release agents, nucleating agents, flowability improvers, antistatic agents, compatibilizers, or anti-dripping agents. In some aspects, the polymeric composition may contain both pigments and plasticizers.

[0044] In some respects, the polymeric composition may contain: i) post-consumer mechanically recycled polycarbonate: 20% to 50% by weight, or at least any one of the following, equal to any one of the following, or between any two of the following: 20% by weight, 25% by weight, 30% by weight, 35% by weight, 40% by weight, 45% by weight, and 50% by weight; ii) renewable source polycarbonate: 10% to 50% by weight, or at least any one of the following, equal to any one of the following, or between any two of the following: 10% by weight, 15% by weight, 20% by weight, 25% by weight, 30% by weight, 35% by weight, 40% by weight, 45% by weight, and 50% by weight; iii) carbon fiber-containing filler: 10% to 30% by weight, or at least any one of the following, equal to any one of the following, or between any two of the following: 10% by weight, 15% by weight, 20% by weight, 25% by weight, and 30% by weight. The carbon fiber described herein is at least partially obtained from post-industrial recycled sources; iv) flame retardants of 5 wt% to 15 wt%, or at least any one of the following, equal to any one of the following, or between any two of the following: 5 wt%, 7 wt%, 9 wt%, 10 wt%, 11 wt%, 13 wt%, and 15 wt%; v) pigments of 0.1 wt% to 3 wt%, or at least any one of the following, equal to any one of the following, or between any two of the following: 0.1 wt%, 0.5 wt%, 1 wt%, 1.5 wt%, 2 wt%, 2.5 wt%, and 3 wt%; and vi) plasticizers of 0 to 5 wt%, or at least any one of the following, equal to any one of the following, or between any two of the following: 0, 0.5 wt%, 1 wt%, 1.5 wt%, 2 wt%, 2.5 wt%, 3 wt%, 3.5 wt%, 4 wt%, 4.5 wt%, and 5 wt%. The polymeric composition may have a total recoverable and renewable content of 50% to 90% by weight, or at least any one of the following, equal to any one of the following, or between any two of the following: 50% by weight, 55% by weight, 60% by weight, 65% by weight, 70% by weight, 75% by weight, 80% by weight, 85% by weight, and 90% by weight.

[0045] 1. Polycarbonate

[0046] Polycarbonates, such as post-consumer mechanically recycled polycarbonates and renewable source polycarbonates, may contain carbonate units. The carbonate units may have the chemical formula (1).

[0047]

[0048] R 1 The radical can contain aliphatic or aromatic groups. The carbonate unit can be derived from sugars, hydroxyl-containing aliphatic groups, and / or hydroxy aromatic groups. Post-consumer mechanical recycling of polycarbonate and polycarbonate from renewable sources yields R... 1 The functional groups can be the same or different. In some respects, the carbonate unit can be derived from bisphenol A (BPA), for example, a carbonate unit having the chemical formula (2).

[0049]

[0050] Polycarbonate can be a homopolymer and / or a copolymer. In polycarbonate homopolymers, each R in the polymer... 1 The functional groups can be the same. Polycarbonate copolymers can contain different R groups. 1 Polycarbonate groups, or carbonate units (having the same or different R groups) 1 Polymers of other types of polymer units (e.g., ester units).

[0051] Post-consumer mechanically recycled polycarbonate can be obtained at least in part by mechanically recycling post-consumer waste containing polycarbonate. Post-consumer polycarbonate waste can be mechanically recycled using mechanical recycling methods known in the art. Mechanical recycling of a polymer refers to the recovery of a polymer from polymer-containing waste through a physical process in which the polymer chains do not break (e.g., chemically depolymerize) into monomer units that form the polymer. In some aspects, mechanical recycling may include steps of grinding, washing, separating, drying, regranulation, and compounding, each of which may occur 0 to more than 10 times. In some aspects, the mechanically recycled content in post-consumer mechanically recycled polycarbonate may be, or post-consumer mechanically recycled polycarbonate may have the following recycled content: 80% to 100% by weight, or 90% to 100% by weight, or 95% to 100% by weight, or 98% to 100% by weight, or 99% to 100% by weight, or about 100% by weight, with the remainder optionally being virgin polycarbonate.

[0052] Post-consumer mechanically recycled polycarbonate may contain polycarbonate homopolymers and / or copolymers. In some aspects, post-consumer mechanically recycled polycarbonate may contain carbonate units derived from bisphenol A (BPA) (e.g., Formula 2). In some aspects, post-consumer mechanically recycled polycarbonate may contain homopolymers containing carbonate units derived from BPA. In some aspects, post-consumer mechanically recycled polycarbonate may contain copolymers containing carbonate units derived from BPA and other carbonate units and / or other types of polymer units. In some aspects, post-consumer mechanically recycled polycarbonate may comprise combinations of polycarbonate polymers.

[0053] Renewable polycarbonate can be obtained at least partially from renewable feedstocks. Renewable polycarbonate can be any suitable polycarbonate known in the art. Renewable polycarbonate can be obtained from renewable feedstocks using methods known in the art. Renewable polycarbonate can include polycarbonate homopolymers and / or copolymers. In some aspects, renewable polycarbonate can contain homopolymers containing carbonate units derived from BPA (e.g., Formula 2). In some aspects, renewable feedstocks can be oilseeds, sugars, castor meal, and / or CO2, such as CO2 obtained from industrial waste. In some aspects, renewable polycarbonate can contain carbonate units derived from sugars. In some particular aspects, renewable polycarbonate can be obtained by reacting sugars with CO2. Non-limiting examples of sugars include ribose, glucose, mannose, and / or xylose. In some aspects, at least a portion of the CO2 can be obtained from industrial waste. In some aspects, the sugar can be a thymidine group and / or the sugar portion of a thymidine derivative. In some aspects, renewable-source polycarbonate can be a polycarbonate-polyester copolymer containing ester units derived from sebacic acid. In some particular aspects, renewable-source polycarbonate can be a polycarbonate-polyester copolymer containing ester units derived from sebacic acid and carbonate units derived from BPA. Sebacic acid can be obtained from castor meal. In some aspects, renewable-source polycarbonate can be obtained from a feedstock obtained from oilseed oil from wood pulp. In some aspects, renewable-source polycarbonate can contain carbonate units derived from BPA, wherein BPA is obtained from a feedstock obtained from oilseed oil from wood pulp. In some aspects, renewable-source polycarbonate can be a homopolymer containing carbonate units derived from BPA, wherein BPA is obtained from a feedstock obtained from oilseed oil from wood pulp. In some aspects, renewable-source polycarbonate can be obtained from phenol and acetone, wherein phenol and / or acetone can be obtained at least partially from renewable feedstock alone. In some aspects, renewable source polycarbonate can be a BPA polycarbonate homopolymer obtained from phenol and acetone, wherein the phenol and / or acetone can be obtained at least partially from renewable raw materials alone. In some aspects, at least a portion of the carbon in the renewable source polycarbonate can be derived from renewable raw materials. In some aspects, at least a portion of the oxygen and / or hydrogen in the renewable source polycarbonate can be derived from non-renewable sources. In some aspects, at least 70%, at least 80%, at least 90%, at least 95%, or 100% of the carbon in the renewable source polycarbonate can be derived from renewable raw materials. In some aspects, renewable source polycarbonate can be a homopolymer containing carbonate units derived from BPA.

[0054] In some aspects, the following renewable source polycarbonates can be produced from renewable raw materials: 13% to 65% by weight, or at least any one of the following, equal to any one of the following, or between any two of the following: 13% by weight, 15% by weight, 20% by weight, 25% by weight, 30% by weight, 35% by weight, 40% by weight, 45% by weight, 50% by weight, 55% by weight, 60% by weight, and 65% by weight. In some aspects, renewable source polycarbonates may comprise combinations of polycarbonate polymers.

[0055] 2. Carbon fiber

[0056] Carbon fiber can be at least partially recycled industrial post-use carbon fiber (e.g., obtained through recycling industrial post-use waste). Carbon fiber can be any suitable carbon fiber. The fiber can be sized, unsized, continuous, diced, seeded, or discontinuous, or any combination thereof. Sizing fibers can be sized with a suitable sizing agent. The fiber can have a suitable length and diameter. Carbon fiber can contain standard modulus, intermediate modulus, and / or high modulus carbon. In some respects, the fiber can be supplied in bundles.

[0057] In some aspects, carbon fibers may have an average length of 1 mm to 100 mm, or at least any one of the following, equal to any one of the following, or between any two of the following: 1 mm, 10 mm, 20 mm, 30 mm, 40 mm, 50 mm, 60 mm, 70 mm, 80 mm, 90 mm, and 100 mm. In some aspects, carbon fibers may have an average filament diameter of 1 μm to 30 μm, or at least any one of the following, equal to any one of the following, or between any two of the following: 1 μm, 5 μm, 10 μm, 15 μm, 20 μm, 25 μm, and 30 μm. In some aspects, carbon fibers may have a sizing content of 0.5 wt% to 10 wt%, or at least any one of the following, equal to any one of the following, or between any two of the following: 0.5 wt%, 1 wt%, 2 wt%, 3 wt%, 4 wt%, 5 wt%, 6 wt%, 7 wt%, 8 wt%, 9 wt%, and 10 wt%. In some respects, carbon fibers can have carbon densities of 1.5 g / cc to 2 g / cc, or 1.75 g / cc to 1.85 g / cc, or at least any one of the following, equal to any one of the following, or between any two of the following: 1.5 g / cc, 1.6 g / cc, 1.7 g / cc, 1.75 g / cc, 1.78 g / cc, 1.8 g / cc, 1.85 g / cc, 1.9 g / cc, 1.95 g / cc, and 2 g / cc. In some cases, the carbon fibers have a tensile modulus of 30 Msi to 55 Msi, or at least any one of the following, equal to any one of the following, or between any two of the following: 30 Msi, 31 Msi, 32 Msi, 33 Msi, 34 Msi, 35 Msi, 36 Msi, 37 Msi, 38 Msi, 39 Msi, 40 Msi, 41 Msi, 42 Msi, 43 Msi, 44 Msi, 45 Msi, 46 Msi, 47 Msi, 48 Msi, 49 Msi, 50 Msi, 51 Msi, 52 Msi, 53 Msi, 54 Msi, and 55 Msi. In some aspects, the carbon fibers may have a recycled content of 10 wt% to 30 wt%, or at least any one of the following, equal to any one of the following, or between any two of the following: 10 wt%, 15 wt%, 20 wt%, 25 wt%, and 30 wt%. Examples of carbon fibers that can be used include, but are not limited to, those available for purchase from CARBONCONVERSIONS. Available for purchase from CARBONCONVERSIONS Or any combination thereof.

[0058] 3. Flame retardants

[0059] In some aspects, the flame retardant may be obtained at least partially from a renewable source. In some aspects, the renewable content of the flame retardant may be from 10% to 50% by weight, or at least any one of the following, equal to any one of the following, or between any two of the following: 13% by weight, 15% by weight, 20% by weight, 25% by weight, 30% by weight, 35% by weight, 40% by weight, 45% by weight, and 50% by weight. In some aspects, the flame retardant may be a non-halogenated flame retardant. In some aspects, the flame retardant may be a non-halogenated phosphorus-containing flame retardant obtained from bio-based chemicals. In some aspects, the bio-based chemicals may be tannins, tannic acid, phytic acid, isosorbide, bisphenol A, deoxyribonucleic acid (DNA), lignin, or β-cyclodextrin, or any combination thereof. In some aspects, the flame retardant may contain bisphenol A-diphosphate obtained from bio-based chemicals.

[0060] 4. Additives

[0061] Plasticizers, lubricants, and / or mold release agents can also be used. There is significant overlap among these types of materials, which include, for example, phthalates, such as dioctyl-4,5-epoxy-hexahydrophthalate; tri-(octyloxycarbonylethyl)isocyanurate; glyceryl tristearate; di- or polyfunctional aromatic phosphates, such as resorcinol tetraphenyl diphosphate (RDP), hydroquinone bis(diphenyl) phosphate, and bisphenol A bis(diphenyl) phosphate; poly-α-olefins; epoxidized soybean oil; silicones, including silicone oils; esters, such as fatty acid esters, such as alkyl octadecyl esters, such as methyl stearate; octadecyl stearate, pentaerythritol tetrastearate, and the like; mixtures of methyl stearate and hydrophilic and hydrophobic nonionic surfactants (including polyethylene glycol polymers, polypropylene glycol polymers, and copolymers thereof), such as methyl stearate and polyethylene-polypropylene glycol copolymers in suitable solvents; waxes, such as beeswax, lignite wax, paraffin wax, or the like.

[0062] For example, colorants such as pigments and / or dye additives can also be present in the polymeric composition. Suitable pigments include, for example, inorganic pigments, such as metal oxides and mixed metal oxides, such as zinc oxide, titanium dioxide, iron oxide, or the like; sulfides, such as zinc sulfide or the like; aluminates; sodium thiosilicate sulfate, chromates, or the like; carbon black; zinc ferrite; ultramarine; pigment brown 24; pigment red 101; pigment yellow 119; organic pigments, such as azo, diazo, quinacridone, perylene, naphthalenetetracarboxylic acid, ochratoxinone, isoindolinone, tetrachloroisoindolinone, anthraquinone, anthraquinone, dioxazine, phthalocyanine, and azo lakes; pigment blue 60, pigment red 122, pigment red 149, pigment red 177, pigment red 179, pigment red 202, pigment violet 29, pigment blue 15, pigment green 7, pigment yellow 147, and pigment yellow 150, or any combination thereof.

[0063] In some respects, the polymeric composition may have a density of 1.1 g / cc to 1.4 g / cc, or 1.25 g / cc to 1.35 g / cc, or 1.28 g / cc to 1.38 g / cc, or at least any one of the following, equal to any one of the following, or between any two of the following: 1.1 g / cc, 1.2 g / cc, 1.25 g / cc, 1.28 g / cc, 1.29 g / cc, 1.3 g / cc, 1.35 g / cc, and 1.4 g / cc, as measured according to ASTM D 792 at 23°C. In some aspects, the polymeric composition may have a tensile modulus at 23°C and measured at 1 mm / min as per ISO 527-1 and ISO 527-2, equal to or greater than 17,000 MPa, or from 17,000 MPa to 22,000 MPa, or from 17,000 MPa to 20,000 MPa, or at least any one of the following, equal to any one of the following, or between any two of the following: 17,000 MPa, 17,500 MPa, 18,000 MPa, 18,500 MPa, 19,000 MPa, 19,500 MPa, 20,000 MPa, 21,000 MPa, and 22,000 MPa. In some aspects, the polymeric composition may have a tensile breaking strength at 23°C, measured at 5 mm / min according to ISO 527-1 and ISO 527-2, equal to or greater than 155 MPa, or 155 MPa to 190 MPa, or 150 MPa to 170 MPa, or at least any one of the following, equal to any one of the following, or between any two of the following: 155 MPa, 160 MPa, 165 MPa, 170 MPa, 175 MPa, 180 MPa, 185 MPa, and 190 MPa. In some aspects, the polymeric composition may have a tensile elongation at break, measured at 1 mm / min according to ISO 527-1 and ISO 527-2, ≥1.1%, ≥1.3%, ≥1.4%, or greater than 5%, or greater than 10%. In some aspects, the polymeric composition may have a flexural modulus at 23°C, measured at 2 mm / min according to ISO 178, equal to or greater than 15500 MPa, or from 15500 MPa to 19000 MPa, or from 16500 MPa to 17500 MPa, or at least any one of the following, equal to any one of the following, or between any two of the following: 15500 MPa, 16000 MPa, 16500 MPa, 17000 MPa, 17500 MPa, 18000 MPa, 18500 MPa, and 19000 MPa. The polymeric composition may have any one, any combination, or all of the properties described in this paragraph.

[0064] B. Methods for manufacturing polymeric compositions

[0065] The thermoplastic compositions of the present invention can be manufactured using various methods known in the art, such as extrusion, injection molding, compression molding, blow molding, rotational molding, thermoforming, 3D printing, or any combination thereof. For example, components such as post-consumer mechanically recycled polycarbonate, renewable source polycarbonate, carbon fiber, flame retardant, and / or optional additives can be mixed together and then melt-blended to form a polymeric composition.

[0066] In some aspects, one or any of the aforementioned components described herein can be first dried and blended together with each other, or with any combination of the aforementioned components, and then fed into the extruder from one or more feeders, or fed separately into the extruder from one or more feeders. The extruder used in this invention can have a single screw, multiple screws, meshing co-rotating or counter-rotating screws, non-meshing co-rotating or counter-rotating screws, reciprocating screws, pinned screws, screws with sieves, pinned barrels, rolls, rams, helical rotors, co-kneaders, disc assembly processors, various other types of extrusion equipment, or combinations comprising at least one of the foregoing. The extruder can generally operate at temperatures higher than those required to melt and flow the composition. In some aspects, the temperature of the melt in the extruder barrel can be maintained as low as possible to avoid excessive thermal degradation of the components. The molten composition exits the extruder through a small exit hole in the die. The extrudate can be quenched in a water bath and then pelletized. The pellets thus prepared can have any desired length (e.g., a quarter inch or less). These particles can be used for subsequent molding, shaping, or forming.

[0067] Mixtures comprising any combination of the aforementioned components may undergo multiple blending and forming steps if necessary. For example, the polymeric composition may first be extruded and then formed into granules. The granules can then be fed into a molding machine, where they can be formed into any desired shape or product. In some aspects, thermoplastic compositions derived from a single melt stirrer can be formed into sheets or strands and subjected to post-extrusion processing, such as uniaxial or biaxial oriented annealing.

[0068] C. Products

[0069] The polymeric compositions of the present invention can be included in articles. Various aspects of this disclosure also relate to articles comprising the polymeric compositions described herein. In some aspects, the articles can be films, sheets, molded articles, welded articles, filaments, or powders. In one example, the composition can be incorporated into a film. The film can comprise at least one film layer comprising a thermoplastic composition. In other aspects, the film comprises at least a second film layer. Other film layers may comprise other materials.

[0070] Articles can be consumer goods. In some respects, articles can be computer parts. A computer can be a desktop computer, a laptop computer, a mobile phone, a tablet computer, a calculator, or the like. In some particular respects, articles can be computer cases or case parts, such as desktop computer cases or case parts or laptop computer cases or case parts.

[0071] refer to Figure 2 This diagram illustrates a laptop or notebook computer 100. Figure 2 A and Figure 2 B shows a front view and a side view of device 100. The laptop or notebook computer 100 may have a keyboard 101, a mouse pad 102, a screen / monitor 103, a top cover 104, a bottom cover 105, and a rear cover 107. In some aspects, the chassis may include at least a portion of the top cover 104, bottom cover 105, or rear cover 107, or any combination thereof, or all of them. The bottom cover 105 may have spaces / holes 106a-106e for one or more ports (e.g., including but not limited to USB ports, HDMI ports, SD card ports, VGA connector ports, microphone and / or speaker ports, laptop charger ports, laptop lock slots, and / or Ethernet ports), said ports being configured to attach peripheral devices (e.g., printers, scanners, storage drives, monitors, speakers, microphones, webcams, USB cables and / or drives, chargers, laptop locks, Ethernet cables, and / or SD cards) to the laptop computer. In some respects, the top cover 104 and / or the rear cover 107 may have one or more holes (not shown) for one or more ports. Figure 2 C and Figure 2 D shows the top cover 104 and the bottom cover 105, respectively. A laptop computer or notebook computer may have a central processing unit (CPU), storage unit, graphics processing unit, random access memory, sound card, speaker, webcam, microphone, motherboard, and / or battery (not shown) located in the space between cover 104 and cover 105 and / or between screen / display 103 and rear cover 107. In some aspects, the top cover 104, bottom cover 105, and / or rear cover 107 may contain the polymeric composition described herein. In some aspects, independently, at least 70% by weight (e.g., 70% to 100% by weight) of the top cover 104, bottom cover 105, and / or rear cover 107 may contain the polymeric composition described herein. Independently, at least 70% by weight (e.g., 70% to 100% by weight) of the top cover 104, bottom cover 105, and / or rear cover 107 may contain recyclable and / or renewable materials, wherein the recyclable and / or renewable materials contain plastics and / or carbon fibers.

[0072] refer to Figure 3A schematic diagram of a desktop computer 200 is shown. The desktop computer 200 may include a monitor 201 and a computer chassis 202. The monitor 201 may have a display screen 204 and a housing 205. In some aspects, the chassis may include at least a portion of the computer chassis 202 or housing 205, or any combination thereof or all of them. The computer chassis 202 may house various computer hardware, including but not limited to a CPU, storage unit, graphics processing unit, random access memory, sound card, and / or motherboard (not shown). The computer chassis 202 may have one or more holes / spaces 203a-203c to attach various computer hardware and peripherals (e.g., media drives such as CD drives, printers, scanners, storage drives, monitors, speakers, microphones, webcams, USB cables and / or drives, chargers) to the computer, for example, through various ports. In some aspects, the computer chassis 202 and / or housing 205 may contain the polymeric compositions described herein. In some aspects, independently, at least 70% by weight (e.g., 70% to 100% by weight) of the computer housing 202 and / or shell 205 may contain the polymeric composition described herein. Independently, at least 70% by weight (e.g., 70% to 100% by weight) of the computer housing 202 and / or shell 205 may contain recyclable and / or renewable materials, wherein the recyclable and / or renewable materials contain plastics and / or carbon fibers.

[0073] refer to Figure 4 The diagram shows a tablet computer or mobile phone 300. Figure 4 A and Figure 4 B shows a front view and a side view of device 300. The tablet computer or mobile phone 300 may include a display screen 301 and a rear panel 302. In some aspects, the chassis may include at least a portion of the rear panel 302. Various tablet computer or mobile phone hardware may be housed between the display screen 301 and the rear panel 302, including, but not limited to, processors, computer chips, cameras, microphones, speakers, and / or batteries. In some aspects, the rear panel may be a foldable panel. In some aspects, at least 70% by weight (e.g., 70% to 100% by weight) of the rear panel 302 may contain the polymeric composition described herein. At least 70% by weight (e.g., 70% to 100% by weight) of the rear panel 302 may contain recyclable and / or renewable materials, wherein the recyclable and / or renewable materials contain plastics and / or carbon fibers.

[0074] In the context of this invention, at least 20 aspects are described. Aspect 1 relates to a polymeric composition comprising: 20% to 50% by weight of post-consumer mechanically recycled polycarbonate; 10% to 50% by weight of renewable source polycarbonate; 10% to 30% by weight of a filler comprising carbon fibers, wherein at least a portion of the carbon fibers is obtained from an industrial post-use recycled source; and 5% to 15% by weight of a flame retardant, wherein the polymeric composition comprises a total recycled and renewable content of 50% to 90% by weight. Aspect 2 relates to the polymeric composition of aspect 1, wherein the renewable source polycarbonate is at least partially produced from renewable feedstocks. Aspect 3 relates to the polymeric composition of aspect 2, wherein the renewable feedstock comprises oilseed oil, castor seeds, sugar, or waste carbon dioxide (CO2), preferably oilseed oil. Aspect 4 relates to the polymeric composition of any one of aspects 1 to 3, wherein 10% to 30% by weight of the carbon fibers is obtained from an industrial post-use recycled source. Aspect 5 relates to the polymeric composition of any one of Aspects 1 to 4, wherein the carbon fiber is a standard modulus fiber, a medium modulus fiber, and / or a high-strength carbon fiber. Aspect 6 relates to the polymeric composition of any one of Aspects 1 to 5, wherein the flame retardant is obtained from a renewable source. Aspect 7 relates to the polymeric composition of Aspect 6, wherein the flame retardant is a non-halogenated phosphorus-containing flame retardant obtained from bio-based chemicals. Aspect 8 relates to the polymeric composition of any one of Aspects 1 to 7, wherein the polymeric composition further comprises additives, wherein the additives are pigments, plasticizers, antioxidants, UV stabilizers, heat stabilizers, dye enhancers, lubricants, release agents, nucleating agents, flowability improvers, antistatic agents, compatibilizers, or anti-dripping agents, or any combination thereof. Aspect 9 relates to the polymeric composition of Aspect 8, wherein the polymeric composition comprises 0.1% to 3% by weight of pigment and 0% to 5% by weight of plasticizer.Aspect 10 relates to a polymeric composition according to any one of Aspects 1 to 9, wherein the polymeric composition comprises any one, a combination of, or all of the following properties: a density of 1 g / cc to 1.4 g / cc as measured according to ASTM D792 at 23°C; a tensile modulus equal to or greater than 17000 MPa or from 17000 MPa to 22000 MPa as measured at 1 mm / min as measured according to ISO 527-1 or ISO 527-2 at 23°C; a tensile breaking strength equal to or greater than 155 MPa or from 155 MPa to 190 MPa as measured at 5 mm / min as measured according to ISO 527-1 or ISO 527-2 at 23°C; a tensile elongation at break equal to or greater than 1.1% as measured at 5 mm / min as measured according to ISO 527-1 or ISO 527-2 at 23°C; and / or a tensile breaking elongation at 23°C as measured according to ISO 527-1 or ISO 527-2 at 5 mm / min; and / or a tensile breaking elongation at 23°C as measured according to ISO 527-1 or ISO 527-2 at 5 mm / min. 178. A flexural modulus greater than 15500 MPa or between 15500 MPa and 19000 MPa, measured at 2 mm / min. Aspect 11 relates to a polymeric composition as described in any one of Aspects 1 to 10, wherein the composition is contained in a film, layer, or sheet. Aspect 12 relates to a polymeric composition as described in any one of Aspects 1 to 11, wherein the composition is an extrusion, blow molding, injection molding, rotational molding, compression molding, 3D printing, and / or thermoforming composition. Aspect 13 relates to a polymeric composition as described in any one of Aspects 1 to 12, wherein the composition is contained in an article of manufacture. Aspect 14 relates to a polymeric composition as described in Aspect 13, wherein the article of manufacture is a computer component. Aspect 15 relates to a polymeric composition as described in any one of Aspects 13 to 14, wherein the article of manufacture is a desktop computer chassis or chassis component or a laptop computer chassis or chassis component. Aspect 16 relates to a computer chassis comprising a polymeric composition as described in any one of Aspects 1 to 12. Aspect 17 relates to a computer chassis as described in Aspect 16, wherein the computer chassis is a desktop computer chassis, a laptop computer chassis, or a tablet computer chassis. Aspect 18 relates to a computer chassis according to any one of Aspects 16 to 17, wherein at least 70% by weight of the computer chassis comprises recyclable and / or renewable materials, wherein the recyclable and / or renewable materials comprise plastics and / or carbon fibers. Aspect 19 relates to a method of manufacturing a computer chassis according to any one of Aspects 16 to 18, the method comprising obtaining a polymeric composition according to any one of Aspects 1 to 12, and forming at least a portion of the computer chassis with the polymeric composition. Aspect 20 relates to the method of Aspect 19, wherein at least 70% by weight of the computer chassis comprises recyclable and / or renewable materials, wherein the recyclable and / or renewable materials comprise plastics and / or carbon fibers.

[0075] Example

[0076] The invention will be described in more detail with the aid of specific examples. The following examples are provided for illustrative purposes only and are not intended to limit the invention in any way. Those skilled in the art will readily identify various non-critical parameters that can be changed or modified to produce substantially the same results.

[0077] Example 1

[0078] The polymer resin composition of the present invention

[0079] Table 1 provides non-limiting resin compositions of the present invention.

[0080] Table 1: Resin Compositions

[0081]

[0082]

[0083] The components in Table 1 are dried, blended, and melt-extruded to form a molded composition containing the resin in Table 1.

[0084] The mechanical properties of the molding compositions were tested using standard methods. The molding resin compositions in Table 1 have a density of 1.29 g / cc as measured according to ASTM D 792, a tensile modulus of 19010 MPa (5 mm / min) as measured according to ASTM D638, a tensile strength at break of 160 MPa (Type 1, 5 mm / min) as measured according to ASTM D638, and an elongation at break of 1.1% at 5 mm / min as measured according to ASTM D638 (Type 1, 5 mm / min).

[0085] The components in Table 1 are dried, blended, and melt-extruded to form granules containing the resin in Table 1. The granules are then injection molded to form a 1.2 mm to 1.6 mm thick back panel for a laptop computer.

[0086] A second composition having the same weight percentage of similar components (e.g., containing a second post-consumer mechanically recycled polycarbonate, a second renewable source polycarbonate, a second industrial post-recycled carbon fiber, a flame retardant, and a pigment) is prepared. The mechanical properties of the molded second composition are tested using standard methods. The molded second composition has a tensile modulus of 19,500 MPa at 23°C, measured at 1 mm / min according to ISO 527-1 and ISO 527-2; a tensile strength at break of 165 MPa at 23°C, measured at 5 mm / min according to ISO 527-1 and ISO 527-2; an elongation at break of 1.3% at 23°C, measured at 5 mm / min according to ISO 527-1 and ISO 527-2; and a flexural modulus of 17,000 at 2 mm / min according to ISO 178.

[0087] Although embodiments and their advantages have been described in detail in this application, it should be understood that substitutions and modifications may be made without departing from the spirit and scope of the embodiments as defined in the appended claims. Furthermore, the scope of this application is not intended to be limited to the specific embodiments of the processes, machines, manufactures, compositions of matter, means, methods, and steps described in the specification. As those skilled in the art will readily understand from the foregoing disclosure, processes, machines, manufactures, compositions of matter, apparatuses, methods, or steps existing or developed later using the corresponding embodiments described herein can perform substantially the same function or achieve substantially the same results. Accordingly, the appended claims are intended to include such processes, machines, manufactures, compositions of matter, apparatuses, methods, or steps within the scope of the claims.

Claims

1. A polymeric composition comprising: 20% to 50% by weight of post-consumer mechanically recycled polycarbonate; From 10% to 50% by weight of renewable source polycarbonate, wherein at least a portion of the renewable source polycarbonate is renewable; 10% to 30% by weight of a filler containing carbon fibers, wherein at least a portion of the carbon fibers is obtained from post-industrial recycled sources; and 5% to 15% by weight of flame retardant, The polymeric composition contains 50% to 90% by weight of total recycled and renewable content.

2. The polymeric composition of claim 1, wherein the renewable source polycarbonate is at least partially produced from renewable raw materials, such that the renewable content is from 13% to 65% by weight of the renewable source polycarbonate.

3. The polymer composition of claim 2, wherein the renewable raw material comprises oil, castor seeds, sugar, or waste carbon dioxide (CO2).

4. The polymeric composition of claim 1, wherein 10% to 30% by weight of the carbon fiber is obtained from an industrial post-use recycled source.

5. The polymer composition of claim 1, wherein the carbon fiber is a standard modulus fiber, a medium modulus fiber, and / or a high-strength carbon fiber.

6. The polymeric composition of claim 1, wherein the flame retardant is obtained from a renewable source.

7. The polymeric composition of claim 6, wherein the flame retardant is a non-halogenated phosphorus-containing flame retardant obtained from bio-based chemicals.

8. The polymeric composition of claim 1, further comprising an additive, wherein the additive is a pigment, plasticizer, antioxidant, UV stabilizer, heat stabilizer, dye enhancer, lubricant, release agent, nucleating agent, flowability improver, antistatic agent, compatibilizer or anti-dripping agent, or any combination thereof.

9. The polymeric composition of claim 8, wherein the polymeric composition comprises 0.1% to 3% by weight of pigment and 0% to 5% by weight of plasticizer.

10. The polymeric composition of claim 1, wherein the polymeric composition comprises any one or a combination of the following properties: Density from 1 g / cc to 1.4 g / cc as measured according to ASTM D792 at 23°C; The tensile modulus equal to or greater than 17000 MPa, measured at 1 mm / min according to ISO 527-1 and ISO 527-2 at 23°C; Tensile breaking strength equal to or greater than 155 MPa, measured at 23°C and at 5 mm / min according to ISO 527-1 and ISO 527-2. Elongation at break equal to or greater than 1.1% when measured at 5 mm / min at 23°C according to ISO 527-1 and ISO 527-2; and / or The flexural modulus equal to or greater than 15,500 MPa, measured at 2 mm / min according to ISO 178 at 23°C.

11. The polymeric composition of claim 1, wherein the polymeric composition is contained in a film, layer or sheet.

12. The polymeric composition of claim 1, wherein the polymeric composition is an extrusion, blow molding, injection molding, rotational molding, compression molding, 3D printing, or thermoforming polymeric composition.

13. The polymeric composition of claim 1, wherein the polymeric composition is contained in the article of manufacture.

14. The polymeric composition of claim 13, wherein the article is a computer part.

15. The polymeric composition of claim 13, wherein the article is a desktop computer chassis or a desktop computer chassis part or a laptop computer chassis or a laptop computer chassis part.

16. A computer chassis comprising the polymeric composition of claim 1.

17. The computer chassis of claim 16, wherein the computer chassis is a desktop computer chassis, a laptop computer chassis, or a tablet computer chassis.

18. The computer chassis of claim 16, wherein at least 70% by weight of the computer chassis comprises recyclable and / or renewable materials, wherein the recyclable and / or renewable materials comprise plastics and / or carbon fibers.

19. A method of manufacturing a computer chassis as claimed in claim 16, the method comprising obtaining a polymeric composition as claimed in claim 1, and forming at least a portion of the computer chassis with the polymeric composition.

20. The method of claim 19, wherein at least 70% by weight of the computer chassis comprises recyclable and / or renewable materials, wherein the recyclable and / or renewable materials comprise plastics and / or carbon fibers.

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