Description:FIELD OF THE INVENTION
[0001] The present invention relates to the field of polymer recycling and sustainable materials. More specifically, the present invention relates to the NeoCycling and Upcycling of sustainable waste High Impact Polystyrene (HIPS) comprising of post-consumer food cups, refrigerator linings, and additives, which offers environmentally friendly, cost-effective, and high-performance plastic suitable for various industrial applications. The present invention also relates to the method of NeoCycling and Upcycling of waste sustainable high impact polystyrene (HIPS) and Air conditioner (AC) Chassis thereof.

BACKGROUND OF THE INVENTION
[0002] Waste is now a global problem, and one that must be addressed in order to solve the world's resource and energy challenges. Plastics are made from limited resources such as petroleum, and huge advances are being made in the development of technologies to recycle plastic waste among other resources. Mechanical recycling methods to make plastic products and feedstock recycling methods that use plastic as a raw material in the chemical industry have been widely adopted, and awareness has also grown recently of the importance of Thermal recycling as a means of using plastics as an energy source to conserve petroleum resources. Plastic, in many applications, can do a better job at a lower cost than other materials.

[0003] In the field of polymer technology, there has been significant progress in recycling of polystyrene. However, traditional recycling often results in lower-grade materials with compromised mechanical properties. Here we can incorporate some processes already in existence.

[0004] Polystyrene is widely used in the food and appliance industries due to its lightweight and insulating properties. However, the disposal of post-consumer food-grade cups and refrigerator linings poses significant environmental concerns.

[0005] As disclosed in the prior arts, one of the processes involved adding, mixing and melt kneading of binder, dispersant and plasticizer with recycled polystyrene resin along with carbon particles. This process is purposed to produce flame retardant recycled polystyrene resin but not virgin polystyrene. And in present scenario, where the concern is to reduce carbon footprint, carbon being a part of composition. Also, this work is not purposed to produce AC chassis.

[0006] In another prior art, it is disclosed that some other recycling processes anti-aging HIPS was produced involving steps like cleaning of recycled HIPS by using limonene and imidazole bromide, adding antioxidant and a toughening agent was added to carry out regeneration. Whereas, proposed invention has steps of collection and sorting, cleaning pre-treatment, shredding and extrusion and additive integration. And compounds involved are used ice cream cups and refrigerator inner lining. And the final product is AC chassis, which is not produced till date.

In some other recycling processes steps of recycling of polystyrene were dissolving the polystyrene based material in a high-boiling, apolar, organic reaction solvent , heating the polystyrene contained in the reaction solvent to a temperature so as to release halogen from the flame retardant, contacting release halogen with a base to form a halogen residue, removing halogen residue, pyrolyzing, depyrolyzing to remove reaction solvent at a temperature and then distilling the depyrolized mixture into at least a styrene fraction. For recycling expanded polystyrene, the method and installation additionally comprise a step of compacting expanded polystyrene in a compaction solvent, where after preferably the compaction solvent is at least partly replaced by the reaction solvent. Virgin HIPS production is energy-intensive and reliant on non-renewable resources.

[0007] The proposed invention involves development of sustainable HIPS by using used ice cream cups and refrigerator inner lining and thereby producing AC chassis, which was earlier not produced by using above mentioned compounds. As plastic wastes and greenhouse gas emissions from ice cream cups and refrigerators can harm ecosystems and disrupt wildlife habitats. Refrigerant leaks and energy consumption contribute to climate change, leading to rising temperatures, sea levels, and extreme weather events. Exposure to micro plastics and pollutants from waste can pose risks to human health. Proper recycling of plastic cups and refrigerator parts can reduce the amount of waste going to landfills. Therefore, there is a need for an alternative method to utilize the used ice cream cups and refrigerator linings, which produce significant waste generation and plastic pollution. Further, there is a need for a sustainable recycling process that maintains the strength, flexibility, and impact resistance of HIPS while reducing environmental impact is the motivation behind this invention.

OBJECTS OF THE INVENTION
Some of the objects of the present disclosure, with atleast one embodiment herein satisfy, are listed herein below:

[0008] The main objectives of the present invention is to develop a sustainable recycling process for converting food-grade cups and refrigerator linings into high-performance HIPS, which offers a cost-effective solution that aligns with circular economy principles.

[0009] Yet, it is another object of the present invention to develop a sustainable HIPS which can improve mechanical properties, such as impact strength, flexibility, and durability, comparable to virgin HIPS.

[0010] It is another object of the present invention to provide a process for the development of sustainable high impact polystyrene (HIPS), which reduces carbon footprint and reliance on virgin polymers.

[0011] Yet, it is another object of the present invention to ensure the traceability and purity of recycled materials for industrial usage.

[0012] It is yet another object of the present invention to provide a method for the development of sustainable high impact polystyrene (HIPS) and Air conditioner Chassis thereof.

SUMMARY OF THE INVENTION

[0013] This summary is provided to introduce a recycled and upcycled High Impact Polystyrene (HIPS) composition and method of production, which is further detailed in the description of the invention. The invention focuses on converting post-consumer HIPS waste into high-performance thermoplastic material through advanced compounding and additive technology. The accompanying figures and examples provide illustrative embodiments of the invention and are not intended to limit its scope. Additional technical specifications and process steps are described in the subsequent sections to demonstrate the advantages and industrial applicability of the invention.

[0014] This summary is provided to introduce development of sustainable HIPS by using food-grade cups and refrigerator linings, through a carefully optimized recycling process. And the method of development of sustainable HIPS involves the steps of efficient collection, sorting, and cleaning of food-grade polystyrene waste. The process includes:
• Efficient collection, sorting, and cleaning of food-grade polystyrene waste.
• Blending with performance additives (impact modifiers, stabilizers) to achieve desired mechanical properties.
• Extrusion and pelletisation to produce high-quality HIPS with improved impact resistance and thermal stability.
The resulting product is suitable for use in automotive parts, appliance components, electronics casings, and other industrial applications.
[0015] The present invention relates to a sustainable waste high impact polystyrene (HIPS) comprising of:
70% food-grade cups;
30% refrigerator linings; and
additives comprising of 5% impact modifiers, 1% UV stabilizer, and 2% processing additives;
wherein the food cups, refrigerator linings are recycled in presence of additives to obtain sustainable HIPS.

[0016] The present invention relates to the method of development of sustainable high impact polystyrene (HIPS) comprising the steps of:
a) collecting and sorting food cups and refrigerator linings manually and followed by mechanically sorting to ensure high purity;
b) cleaning and pre-treating of material of step a) by hot water washing and chemical degreasing to remove oils and contaminants to obtain cleaned materials;
c)shredding and feeding the cleaned materials into a twin-screw extruder at a temperature followed by adding impact modifiers, UV stabilizers and processing additives for enhancing impact resistance, thermal stability and durability and to achieve mechanical properties compatible to HIPS to form a melted material;
d) filtering of melted material as obtained in step c) to remove impurities and then pelletization is done for a time period of 1.5 to 2 hrs to obtain resultant sustainable HIPS; and
e) cooling of the Pelletized HIPS and followed by inspection for quality assurance.

The present invention also relates to the development of an Air Conditioner Chassis obtained by upcycling of sustainable HIPS so obtained by up-cycling method.
DESCRIPTION OF THE ACCOMPANYING DRAWING(S)

[0017] It is to be noted, however that the appended drawings illustrate only typical embodiments of the present subject matter and are therefore not to be considered for limiting of its scope, for the invention may admit to other equally effective embodiments.

[0018] Fig 1 shows the food waste raw material & refrigerator linings used for the development of sustainable HIPS.

[0019] Fig. 2 shows the image of a AC Chasis obtained by the Upcycling of waste High Impact Polystyrene (HIPS).

[0020] Fig. 3 shows the image of a granular form of sustainable High Impact Polystyrene (HIPS).

DETAILED DECRIPTION OF THE INVENTION
[0021] In describing the invention, the following terminology will be used in accordance with the definitions set forth below. Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. Although any instrument and component similar or equivalent to those described herein can be used in the practice or testing of the present invention. As used herein, each of the following terms has the meaning associated with it in this section. Specific and preferred values listed below for individual component, and ranges are for illustration only; they do not exclude other defined values or other values falling within the preferred defined ranges.
[0022] The terms "comprise", "comprising", or any other variations thereof, are intended to cover a non-exclusive inclusion, such that a process or method that comprises a list of steps does not include only those steps but may include other steps not expressly listed or inherent to such a process or method. Similarly, one or more devices or sub-systems or elements or structures or components preceded by "comprises... a" does not, without more constraints, preclude the existence of other devices, sub-systems, elements, structures, components, additional devices, additional sub-systems, additional elements, additional structures, or additional components. Appearances of the phrase "in an embodiment", and similar language throughout this specification may, but not necessarily do, all refer to the same embodiment.
[0023] In the following specification and the claims, reference will be made to a number of terms, which shall be defined to have the following meanings. The singular forms “a”, “an”, and “the” include plural references unless the context clearly dictates otherwise.
[0024] The meaning of “polymer recycling and sustainable materials” in the context of the present disclosure are crucial for a circular economy and environmental protection. Polymer recycling involves reprocessing waste plastic into new products, reducing waste and conserving resources. Sustainable materials, on the other hand, are those derived from renewable or recycled resources, minimizing environmental impact throughout their lifecycle. Thus, the present invention relates to the process of recovering and re-using plastic waste to create new products, which is cost-effective, durable, and environmentally friendly, and reduces carbon footprint.

[0025] The meaning of the term “upcycling and recycling” in the context of the present invention refers to both sustainable practices aimed at reducing waste, but they differ in their approach and outcome. Recycling involves breaking down materials into raw materials to create new products, often of a similar or lower value. While the term “Upcycling” in the context of the present disclosure, focuses on creatively reusing existing products or materials to create something new and often of higher value. The method of upcycling involved development of Air conditioner (AC) Chassis from the waste HIPS obtained by up-cycling of the waste raw materials such as post-consumer food cups, refrigerator linings, and additives, which offers environmentally friendly, cost-effective, and high-performance plastic suitable for various industrial applications.

[0026] The present invention discloses Neocycling of Plastic waste, especially packaging waste, is generally a mixture of materials with a high degree of contamination. Recycling this raw material is usually difficult, as sorting and cleaning of waste is in many cases neither economically viable nor technically feasible. Upcycling is a promising process to recycle these material streams into valuable materials. The present technology provides first-class technologies for the chemical recycling of post-consumer waste. Our specialized feeders ensure high-accuracy feeding of raw materials into the extruder.

[0027] The meaning of the phrase “Impact modifiers” in the context of the present disclosure are substances added to polymers to improve their resistance to impact, making them less likely to crack, break, or deform under the extreme stress. They essentially enhance the toughness and durability of the polymer. The “Impact modifiers” used are various styrene butadiene block co polymers. The Impact modifiers used in the present invention is selected from a group comprising of copolymers of Styrene-Butadiene-Styrene (SBS), Styrene-Ethylene-Butadiene-Styrene (SEBS) polymer, Methyl Methacrylate-Butadiene-Styrene (MBS) polymer. The disclosure of the various Impact modifiers used are not limited to the mentioned groups but also includes any kind of permutations and combinations as known in the person skilled in the art that can achieve the desired objective of the present application. Here the said phrases shall be considered in the context of the present disclosure.

[0028] The meaning of the phrase “UV stabilizer” in the context of the present disclosure is a chemical additive incorporated into materials like plastics and coatings to protect them from the damaging effects of ultraviolet (UV) radiation, primarily from sunlight. UV light can cause degradation, discoloration, and loss of mechanical properties in materials, leading to reduced lifespan and structural integrity. UV stabilizers are additives that absorb UV light and convert it into heat, preventing the UV light from causing damage to the polymer. The UV stabilizer used in the present invention is Tinuvin 770. The disclosure of the UV stabilizer used is not limited to the mentioned group but also includes any kind of permutations and combinations as known to the person skilled in the art that can achieve the desired objective of the present application.

[0029] The present invention relates to a sustainable high impact polystyrene (HIPS) comprising of: 70% food-grade cups; 30% refrigerator linings; and additives comprising of 5% impact modifiers, 2% UV stabilizer, and 1% processing additives; wherein the food cups, refrigerator linings are recycled in presence of additives to obtain sustainable waste HIPS.

[0030] In an embodiment of the present disclosure, the sustainable HIPS so obtained is in granular form having a particle size in the range of 0.2 to 2 mm. The disclosure of the range of particle size is not limited to the mentioned range but also includes any kind of permutations and combinations as known to the person skilled in the art that can achieve the desired objective of the present application.

[0031] In another embodiment of the present disclosure, the resulting HIPS having a dry density in the range of 1.01 to 1.06 kg/m3. The disclosure of the range of dry density is not limited to the mentioned range but also includes any kind of permutations and combinations as known to the person skilled in the art that can achieve the desired objective of the present application.

[0032] In another embodiment of the present disclosure the resulting HIPS having a tensile strength in the range of 18 to 22 MPa and flexural strength in the range of 30 to 35 MPa. The disclosure of the range of tensile strength and flexural strength are not limited to the mentioned ranges but also includes any kind of permutations and combinations as known to the person skilled in the art that can achieve the desired objective of the present application.

[0033] In another embodiment of the present disclosure the resulting HIPS having a water absorption of less than 0.5% wt. The disclosure of the absorption percentage is not limited to the mentioned ranges but also includes any kind of permutations and combinations as known to the person skilled in the art that can achieve the desired objective of the present application.

[0034] The present invention relates to the method of neocyling and upcycling of sustainable high impact polystyrene (HIPS) comprising the steps of: a) collecting and sorting food cups and refrigerator linings manually and followed by mechanically sorting to ensure high purity; b)cleaning and pre-treating of material of step a) by hot water washing and chemical degreasing to remove oils and contaminants to obtain cleaned materials; c) shredding and feeding the cleaned materials into a twin-screw extruder at a temperature followed by adding impact modifiers, UV stabilizers and processing additives for enhancing impact resistance, thermal stability and durability and to achieve mechanical properties compatible to HIPS to form a melted material; d) filtering of melted material as obtained in step c) to remove impurities and then pelletization is done for a time period of 1.5 to 2 hrs to obtain resultant sustainable HIPS; e) cooling of the Pelletized HIPS and followed by inspection for quality assurance.

[0035] In another embodiment of the present disclosure, wherein the step of shredding and feeding the material to form a melted material of step c) is carried out at a temperature in the range of 180 to 240°C. The disclosure of the temperature ranges is not limited to the mentioned ranges but also includes any kind of permutations and combinations as known to the person skilled in the art that can achieve the desired objective of the present application.

[0036] In an embodiment of the present disclosure relates to a process of sustainable HIPS development has been developed. Here by recycling of post- consumer food grade cups and refrigerator inner linings, sustainable HIPS is developed. In the process of development of sustainable HIPS, collection and sorting of food grade cups and refrigerator inner linings has been done manually or mechanically and sorting of collected material has been performed to ensure high purity.

[0037] After collection, cleaning and pretreatment of collected material has been done by hot water washing and chemical degreasing to remove oil and contaminants from the surface of the materials.

[0038] Now cleaning and sorting is followed by shredding and extrusion of clean material is performed. This step provides us melted material. This melted material is mixed with impact modifiers, UV stabilizers, and processing aids are added to enhance performance.
[0039] Melted material is filtered to remove impurities before pelletisation. And then pelletisation is performed. Pelletized HIPS is cooled and inspected for quality assurance. Purpose of quality assurance is to perform tensile testing, impact testing and thermal testing to meet industrial standards.
[0040] The process involved here reduces carbon footprint and promotes circular economy principles. Finally, the developed HIPS is utilized to produce AC chassis. Also, the developed HIPS suitable for use in automotive parts, appliance components, electronics casings, and other industrial applications.
[0041] The invention is further illustrated by the following example, which is provided to be exemplary of the invention and does not limit the scope of the invention. While the present invention has been described in terms of its specific embodiments, certain modifications and equivalents will be apparent to those skilled in the art and are intended to be included within the scope of the present invention.
WORKING EXAMPLES AND METHODS:
[0042] Table 1. shows the different characteristic and technical features such as particle size (nm), dry density (kg/m3), tensile strength (MPa), flexural strength (MPa), water absorption (%), and temperature(°C) of the waste HIPS and AC outdoor unit chassis.
Table 1

MATERIALS & METHODS:
[0043] Example 1:
• Input: 70% Food-grade cups + 30% Refrigerator linings
• Additives: 5% Styrene Butadine Copolymer (SBC) for impact strength, 1% UV stabilizer, 2% chain extenders
• Result: Impact strength improved by 20%, tensile strength increased by 15% compared to baseline recycled HIPS.
[0044] Example 2:
• Input: 50% Refrigerator linings + 50% food cups
• Additives: 10% glass fibre reinforcement
• Result: Enhanced stiffness and thermal stability suitable for automotive parts.

ADVANTAGES OF THE INVENTION
[0045] 1. The method involved in the present invention reduces plastic waste and supports circular economy practices and improves environmental sustainability.
[0046] 2. The method of development of sustainable HIPS utilizes post-consumer waste, significantly lowering raw material costs. Hence, the process is cost effective.
[0047] 3. The developed sustainable HIPS is versatile, as it is applicable for automotive, electronics, appliances, and consumer goods.

SPECIFIC EMBODIMENTS OF THE PRESENT DISCLOSURE:
The present invention relates to a sustainable waste high impact polystyrene (HIPS) comprising of:
70% food-grade cups;
30% refrigerator linings; and
additives comprising of 5% impact modifiers, 1% UV stabilizer, and 2% processing additives;
wherein the food cups, refrigerator linings are up-cycled in presence of additives to obtain waste sustainable HIPS.

Such sustainable HIPS is disclosed, wherein the HIPS is in granular form having a particle size in the range of 0.2 to 2 mm.
Such sustainable HIPS is disclosed, wherein the resulting HIPS having a dry density in the range of 1.01 to 1.06 kg/m3.
Such sustainable HIPS is disclosed, wherein the resulting HIPS having a tensile strength in the range of 18 to 22 MPa and flexural strength in the range of 30 to 35 MPa.
Such sustainable HIPS is disclosed, wherein the resulting HIPS having a water absorption of less than 0.5% wt.
The present invention relates to the method of neocyling and upcycling of sustainable high impact polystyrene (HIPS) comprising the steps of:
a) collecting and sorting food cups and refrigerator linings manually and followed by mechanically sorting to ensure high purity;
b) cleaning and pre-treating of material of step a) by hot water washing and chemical degreasing to remove oils and contaminants to obtain cleaned materials;
c) shredding and feeding the cleaned materials into a twin-screw extruder at a temperature followed by adding impact modifiers, UV stabilizers and processing additives for enhancing impact resistance, thermal stability and durability and to achieve mechanical properties compatible to HIPS to form a melted material;
d) filtering of melted material as obtained in step c) to remove impurities and then pelletization is done for a time period of 1.5 to 2 hrs to obtain resultant sustainable HIPS;
e) cooling of the Pelletized HIPS and followed by inspection for quality assurance.
Such method is disclosed, wherein the step of shredding and feeding the material to form a melted material of step c) is carried out at a temperature in the range of 180 to 240°C.
Such method is disclosed, wherein the processing additives is irganox 1010.
Such method is disclosed, wherein the UV stabilizer is Tinuvin 770.
Such method is disclosed, wherein the impact modifiers is selected from a group comprising of Co-polymer of SBS, SEBS, MBS.
The present invention also relates to the development of an Air Conditioner Chassis obtained by upcycling of waste sustainable HIPS.
INDUSTRIAL APPLICATION:
[0001] The present disclosure relates to a polymer recycling and sustainable materials, having a sustainable, non-toxic solution and the process of development is scalable which is adaptable for large-scale industrial production of Air Conditioner Chassis, automotive, electronics, appliances, and consumer goods.
, Claims:We claim:
1. A waste sustainable high impact polystyrene (HIPS) comprising of:
70% food-grade cups;
30% refrigerator linings; and
additives comprising of 5% impact modifiers, 1% UV stabilizer, and 2% processing additives;
wherein the food cups, refrigerator linings are recycled in presence of additives to obtain sustainable waste HIPS.

2. The sustainable HIPS as claimed in claim 1, wherein the resulting HIPS is in granular form having a particle size in the range of 0.2 to 2 nm.
3. The sustainable HIPS as claimed in claim 1, wherein the resulting HIPS having a dry density in the range of 1.01 to 1.06 kg/m3.
4. The sustainable HIPS as claimed in claim 1, wherein the resulting HIPS having a tensile strength in the range of 18 to 22 MPa and flexural strength in the range of 30 to 35 MPa.
5. The sustainable HIPS as claimed in claim 1, wherein the resulting HIPS having a water absorption of less than 0.5% wt.
6. The method of neocyling and upcycling of sustainable high impact polystyrene (HIPS) comprising the steps of:
a) collecting and sorting food cups and refrigerator linings manually and followed by mechanically sorting to ensure high purity;
b) cleaning and pre-treating of material of step a) by hot water washing and chemical degreasing to remove oils and contaminants to obtain cleaned materials;
c) shredding and feeding the cleaned materials into a twin-screw extruder at a temperature followed by adding impact modifiers, UV stabilizers and processing additives for enhancing impact resistance, thermal stability and durability and to achieve mechanical properties compatible to HIPS to form a melted material;
d) filtering of melted material as obtained in step c) to remove impurities and then pelletization is done for a time period of 1.5 to 2 hrs to obtain resultant sustainable HIPS;
e) cooling of the pelletized HIPS and followed by inspection for quality assurance.
7. The method as claimed in claim 6, wherein the step of shredding and feeding the material to form a melted material of step c) is carried out at a temperature in the range of 180 to 240 °C.
8. The method as claimed in claim 6, wherein the processing additives is selected from a group comprising of irganox 1010.
9. The method as claimed in claim 6, wherein the UV stabilizer is Tinuvin 770.
10. The method as claimed in claim 6, wherein the impact modifiers is selected from a group comprising of co-polymer of SBS, SEBS, MBS.
11. An Air Conditioner Chassis developed by upcycling of sustainable HIPS obtained from the method as claimed in claim 6-10.