New recyclable and self-healing elastomer composites using waste from toner cartridges

Product recycling reintroduces what is discarded as waste and minimizes the environmental impact on our society. Among the different types of waste from electrical and electronic equipment, toner recycling often falls short, downcycling plastic components. This study introduces an innovative approach in which waste parts from toner cartridges are valorized to develop (recyclable and) self-healing elastomeric composite materials. The synergy between carboxylated nitrile rubber (XNBR) as the elastomeric phase and high-impact poly (styrene) (HIPS) as the thermoplastic phase derived from toner cartridge waste was explored and optimized. This combination resulted in the creation of a thermoplastic elastomer exhibiting robust mechanical properties and self-healing capabilities with a tensile strength of 6.6 ± 0.2 MPa and a temperature-driven mechanical recovery of 100%. Furthermore, the capacity of toner powder, an integral component of waste, to act as a reinforcing filler was confirmed, with a 50% increase in mechanical strength compared with the unfilled composite. Moreover, an increase in toner content (up to 20 phr) resulted in an optimal balance between tensile strength and self-healing capacity, surpassing the traditional antagonism between these properties. As a result, this research opens a new pathway in the field of self-healing composites and suggests a practical and environmentally friendly approach for managing electronic waste, effectively supporting the principles of Circular Economy.