Color Masterbatch with Acid Dyes for Plastic Decolorization
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Solution Overview
Problem
Current plastic recycling processes are hindered by the difficulty in removing pigments and dyes from plastic articles, leading to undesirable color tones and limited recyclability, with existing methods being costly and environmentally unfriendly.
Innovation Solution
A color masterbatch comprising an organic polymer carrier, acid dyes, and a water-soluble or water-swellable component is used to produce colored plastic articles, allowing for easy decolorization in a recycling bath with a controlled pH and temperature, utilizing a mixture of water, polar solvents, and oxidizing or reducing agents.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If pigments and dyes are used for coloring plastic articles, then the desired color is achieved, but the recycling process is complicated and the pigments cannot be removed during mechanical recycling
Solution Approach 1:
The patent extracts the coloring function from traditional pigments/dyes by using acid dyes that can be removed during recycling. The acid dye is applied to the plastic surface or incorporated in a removable form, allowing the color to be separated from the plastic material during the recycling process, thus resolving the contradiction between achieving desired color and enabling easy recycling
Solution Approach 2:
The patent changes the chemical parameters of the coloring agent by using acid dyes with specific molecular structures that are soluble in aqueous alkali solutions. This parameter change allows the color to be removed under specific recycling conditions (alkaline environment), transforming the recycling process from impossible to feasible while maintaining color quality during use
2Illumination intensity
If strong oxidation or reduction processes are used to chemically modify pigments, then the pigments lose their chromophoric property, but the oxidation or reduction agents are very aggressive and need to be used in high amounts which is not environmentally friendly
Solution Approach 1:
The patent changes the chemical nature of the coloring agent from traditional pigments resistant to oxidation/reduction to acid dyes that are inherently removable under mild alkaline conditions. This parameter change eliminates the need for aggressive oxidation or reduction agents, achieving decolorability without environmental harm
Solution Approach 2:
The patent uses acid dyes that are designed to be temporary and removable, analogous to disposable components. The color is applied effectively during use but can be completely removed under specific conditions, eliminating the need for permanent, hard-to-remove pigments and avoiding the environmental damage caused by strong chemical agents
3Manufacturing precision
If plastic articles are sorted according to color during recycling, then high quality colored recycled material is achieved, but additional sorting processes are required which increase cost and complexity
Solution Approach 1:
The patent extracts the color from the plastic material during recycling by using acid dyes that can be removed under alkaline conditions. This extraction eliminates the need for color-based sorting, as all colored plastics can be processed together and the color is removed uniformly, simplifying the recycling process while maintaining high recyclate quality
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables the efficient decolorization of plastic articles, allowing for the recovery of at least 85% of the plastic material for reuse, without the need for organic solvents, thus enhancing recyclability and environmental sustainability.
Implementation Method 1
the at least one carrier is an organic polymer having a molecular weight Mw ≥ 1000 g/mol and wherein the organic polymer is insoluble in water, wherein an amount of the water-soluble or water-swellable component in the color masterbatch is ≥ 1 wt% to ≤ 50 wt%
Implementation Method 2
wherein an amount of the water-soluble or water-swellable component in the color masterbatch is ≥ 1 wt% to ≤ 50 wt%
Implementation Method 3
the decoloring bath comprises water, at least one polar solvent, and an oxidizing agent or a reducing agent and/or a polar decoloring agent
Implementation Method 4
the decoloring bath comprises water, at least one polar solvent, and an oxidizing agent or a reducing agent and/or a polar decoloring agent
Data Source
AI summary
The present invention is directed to a color masterbatch for producing colored plastic articles, wherein the color masterbatch comprises: - at least one carrier, - at least one coloring agent, and - at least one water-soluble or water-swellable component; wherein the at least one carrier is an organic polymer having a molecular weight Mw ≥ 1000 g/mol and wherein the organic polymer is insoluble in water, wherein an amount of the water-soluble or water-swellable component in the color masterbatch is ≥ 1 wt% to ≤ 50 wt%, preferably ≥ 2 wt% to ≤ 25 wt%, more preferably ≥ 4 wt% to ≤ 20 wt%, even more preferably ≥ 5 wt% to ≤ 15 wt%, based on the total weight of the color masterbatch, wherein the coloring agent is an acid dye, and wherein a weight ratio of the coloring agent to the water-soluble or water-swellable component in the color masterbatch is 1:2 to 1:200, preferably 1:5 to 1:50.