	US 12,240,155 B2
	Co-injection molding of foam articles
Levi A. Kishbaugh, Groveland, MA (US); and Scott E. Ludwig, Nokomis, FL (US)
Assigned to Trexel, Inc., Wilmington, MA (US)
Filed by Trexel, Inc., Wilmington, MA (US)
Filed on Jul. 20, 2022, as Appl. No. 17/869,417.
Prior Publication US 2024/0025090 A1, Jan. 25, 2024
Int. Cl. B29C 44/06 (2006.01); B29C 44/42 (2006.01); B29K 105/00 (2006.01); B29K 105/26 (2006.01); B29L 9/00 (2006.01)

CPC B29C 44/06 (2013.01) [B29C 44/42 (2013.01); B29K 2105/0032 (2013.01); B29K 2105/26 (2013.01); B29K 2995/0039 (2013.01); B29K 2995/004 (2013.01); B29L 2009/00 (2013.01)]

13 Claims

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 of an article;

expanding the mold cavity to permit the core to expand into a foamed core of the article, wherein the first polymeric material forms a skin layer at least partially surrounding the foamed core; and

extracting the article from the mold cavity; and

wherein the first polymeric material comprises a virgin polymer and the second polymeric material comprises a recycled polymer.