Multilayer ABS Article With Recycled Core and Migration Barrier

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Solution Overview

Problem

Existing technologies face challenges in creating high-quality articles using recycled ABS copolymers that meet mechanical requirements and regulatory standards, such as those needed for household applications, while avoiding health risks associated with additive migration.

Innovation Solution

A multilayer article comprising a recycled ABS copolymer core layer encapsulated by a virgin ABS copolymer layer, where the virgin layer forms a discontinuous phase with dispersed spherical particles, preventing additive migration and enhancing mechanical properties.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of energy

If recycled ABS copolymer is used to reduce waste and energy consumption, then environmental benefits are improved, but mechanical properties and safety standards deteriorate

Engineering Contradiction:

Improveenergy consumptionVSAvoidmechanical properties

Core Design Contradiction:

Loss of energyVSStrength

Solution Approach 1:

The article is divided into multiple layers with different functions: an inner layer made of recycled ABS copolymer for structural purposes, and an outer layer made of virgin ABS copolymer for protective and aesthetic functions. This segmentation allows each material to be optimized for its specific role, maintaining mechanical strength while utilizing recycled material where appropriate.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the article have different material compositions tailored to their specific requirements. The inner layer uses recycled material where mechanical properties are sufficient, while the outer layer uses virgin material where higher quality is needed for contact, aesthetics, or durability. This local differentiation optimizes overall performance while maximizing recycled content.

Inventive Principle:

Principle #3Local quality

2Loss of substance

If recycled ABS copolymer is used to reduce waste disposal, then environmental benefits are improved, but health risks from additive migration worsen

Engineering Contradiction:

Improvewaste disposalVSAvoidadditive migration

Core Design Contradiction:

Loss of substanceVSObject-affected harmful factors

Solution Approach 1:

The virgin ABS copolymer outer layer acts as an intermediary barrier between the recycled ABS copolymer inner layer and the external environment. This intermediate layer prevents direct contact and potential additive migration from the recycled material, while still allowing the recycled layer to provide structural benefits. The virgin material serves as a protective interface that eliminates health concerns.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Reliability

If multilayer structure with virgin outer layer is used to prevent additive migration, then health safety is improved, but material cost increases

Engineering Contradiction:

Improvehealth safetyVSAvoidmaterial cost

Core Design Contradiction:

ReliabilityVSQuantity of substance

Solution Approach 1:

Instead of using virgin material throughout the entire article, only the outer layer (the minimum necessary for protection and contact) is made from virgin ABS copolymer. The inner structural layer uses recycled material. This partial application of virgin material provides sufficient health protection and performance while minimizing costs compared to using 100% virgin material.

Inventive Principle:

Principle #16Partial or excessive action

4Quantity of substance

If high proportion of recycled material is used to reduce petroleum consumption, then resource efficiency is improved, but delamination resistance worsens

Engineering Contradiction:

Improvepetroleum consumptionVSAvoiddelamination resistance

Core Design Contradiction:

Quantity of substanceVSStability of the object's composition

Solution Approach 1:

The article uses a composite structure combining recycled ABS copolymer and virgin ABS copolymer in distinct layers. The interface between these layers is designed to prevent delamination, creating a stable composite material system. This composite approach allows high recycled content (30-70% by weight) while maintaining structural integrity and resistance to layer separation through proper material selection and interface design.

Inventive Principle:

Principle #40Composite materials

Data Source

PatentEP4399088B1Multilayer article comprising a recycled ABS copolymer core layer

Publication Date: 2025.11.05 INEOS STYROLUTION GRP GMBH

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AI summary

A multilayer article for applications in the household sector comprises a core layer a) consisting of a recycled plastic material comprising at least one recycled nitrile-diene-vinylaromatic graft copolymer; and a layer b) consisting of a virgin plastic material comprising at least one virgin nitrile-diene-vinylaromatic graft copolymer; wherein the portion of the core layer a) is 20 to 50 wt.-%, and the core layer a) is encapsulated by layer b).