Patent ID: 7976749

Claim:
An injection moulding process for making a completely recyclable, multilayered article consisting of: i) a rigid layer formed of a thermoplastic polymer which comprises as component A1, from 45 to 90% by weight of polybutylene terephthalate, as component A2, from 0 to 30% by weight of polyethylene terephthalate and as component B, from 10 to 25% by weight of an Acrylonitrile Styrene Acrylate (ASA) copolymer and ii) a foamed skin layer formed of a thermoplastic polymer compatible with the material of the rigid layer, wherein in the process consists essentially of injection moulding of the rigid layer into a mould composed of two sides, lifting one side of the mould, or change one side of the mould to obtain a small gap of between 3 to 4 mm between the rigid layer and the side of the mould lifted or changed and injecting the foamed skin layer into the gap formed in step b), wherein the foamed skin layer forming thermoplastic polymer comprising polybutylene terephthalate, wherein the foamed skin layer forming thermoplastic polymer has a multiplicity of repeating long-chain ester units as soft segments and a multiplicity of repeating short-chain ester units as hard segments, said short-chain units being represented by the general formula (I): —O-D-O—CO—R—CO (I) and said long-chain ester units being represented by the general formulas (IIa) and/or (IIb): —O-G-O—CO—R—CO (IIa) —O-D-O—CO-A-CO— (IIb) wherein: D is a divalent radical remaining after the removal of the hydroxyl groups from an alkylene glycol having a molecular weight lower than about 250, 1,4-butanediol being at least a part of the alkylene glycols used, R is a divalent radical remaining after the removal of the carboxyl groups from dicarboxylic acid having a molecular weight lower than about 300, terephthalic acid being at least a part of the dicarboxylic acids used, G is a divalent radical remaining after the removal of the hydroxyl end groups from a long chain glycol having a molecular weight of from about 250 to about 6,000 g. A is a divalent radical remaining after the removal of the carboxyl groups from an unsaturated or saturated long chain dicarboxylic acid having from 1 to 25 carbon atoms and h. O is oxygen wherein component B comprises from 50 to 90% by weight of a particulate graft base B1 made from the following monomers as component B11, from 75 to 99.9% by weight of a C1-C10-alkyl acrylate, as component B12, from 0.1 to 10% by weight of at least one polyfunctional monomer having at least two non-conjugated olefinic double bonds, and as component B13, from 0 to 24.9% by weight of one or more other copolymerizable monomers, and from 10 to 50% by weight of a graft B2 grafted onto graft base B1 and made from the following monomers as component B21, from 50 to 29% by weight of a vinylaromatic monomer, and as component B22, from 10 to 50% by weight of acrylonitrile and/or methacrylonitrile.