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As far as postconsumer recycled plastics are concerned, their
properties are even worse than those of postindustrial materials.
Unlike postindustrial recycled plastics, postconsumer recycled plastics are exposed to a variety of often severe situations during product usage. As a result, their properties are often drastically reduced. Therefore, the traditional applications for postconsumer recycled plastics are restricted to products in which high performance is not required. Common examples are polyester fibers made from recycled PET beverage containers and core materials seen in coinjection molding processes.
If the performance of products containing postindustrial and/or postconsumer recycled materials could be improved, then the consumption of recycled materials would be much higher and the associated amount of material wasted and ending up in landfills would be dramatically reduced. For some time the plastics industry has been searching for new ways to enable wider utilization of recycled materials. The overall plastics recycling field, however,has two major problems: (i) collecting recyclable materials and preparing (cleaning and regranulating) them for future use and (ii) developing capabilities to process recycled materials effectively into new products and/or saleable intermediate materials that meet the needs of suitable existing markets . The second of these two problems would be resolved if a processing technology capable of significantly improving the quality of products made from recycled materials was developed. The focus of the present investigation is one such technology, namely vibration-assisted injection molding (VA I M ).
Vibration-assisted injection molding is a novel manufacturing technique based on the enhancement of final product properties via melt manipulation during processing. Several types of melt manipulation techniques have been investigated to date. The development of these techniques was often targeted at yielding improvements in injection molded parts, and many led to significant property enhancements. Examples of techniques that have been investigated include the SCORIM process, the moving boundary process, the push-pull process, and the RHEOMOLDING process.The author has conducted a comprehensive review of these processing methods elsewhere . However, to date none of these techniques appear to have been explored with the goal of enhancing the utilization of recycled materials. With this in mind, the vibration-assisted injection molding process was utilized during the present study to manufacture products containing recycled polystyrene. The goal of the study was to explore the level to which the mechanical strength of products containing recycled materials could be improved through VAIM.