Aqueous Anchor Layer Laminate for Alkaline Deinking
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Solution Overview
Problem
Existing methods are inadequate for efficiently desorbing active energy ray curing type inks and varnishes from non-absorbent substrates like plastics, leading to difficulties in recycling and increased marine pollution, as these inks are difficult to separate and often contaminate the recycling process.
Innovation Solution
A laminate structure with an anchor layer containing an aqueous resin and an ink layer formed by curing active energy ray curing type inks is developed, where the aqueous resin has a specific acid value and glass transition temperature, allowing for effective deinking using an alkaline solution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If active energy ray curing type inks and varnishes are used on non-absorbent substrates, then curing speed and film strength are improved, but recyclability deteriorates due to difficulty in separating printed materials
Solution Approach 1:
The invention divides the ink system into two functional layers: an anchor layer containing aqueous resin that provides recyclability, and an ink layer containing active energy ray curing type ink that provides fast curing and strong films. This segmentation allows each layer to independently fulfill its specific function without compromising the other.
Solution Approach 2:
The aqueous resin in the anchor layer acts as an intermediary between the non-absorbent substrate and the cured ink layer. It provides a bonding interface that maintains adhesion during use but allows for easy separation during recycling through water-based treatment, thus mediating between the conflicting requirements of durability and recyclability.
2Manufacturing precision
If conventional UV curing systems are used, then print quality is improved, but energy consumption and heat generation increase
Solution Approach 1:
The invention changes the curing parameter from conventional UV light sources to active energy ray (electron beam) irradiation. This parameter change eliminates the need for infrared and excessive ultraviolet regions that generate heat and ozone, while maintaining effective curing. The electron beam energy is more efficiently converted to curing action without unwanted thermal byproducts.
3Object-generated harmful factors
If active energy ray curing type inks are used, then VOC emissions are reduced, but deinking difficulty increases
Solution Approach 1:
The invention changes the chemical parameter of the anchor layer from conventional organic-based resins to aqueous resin. This parameter change makes the anchor layer water-soluble or water-dispersible, enabling easy removal during deinking processes. The aqueous nature of the anchor layer creates a clear separation point in the recycling process where the anchor layer can be washed away with water, leaving the substrate clean and recyclable.
4Device complexity
If material recycling is performed without desorbing inks, then recycling simplicity is improved, but substrate quality deteriorates due to ink contamination
Solution Approach 1:
The invention extracts the anchor layer containing the aqueous resin from the ink system. This extracted anchor layer serves as a sacrificial component that can be easily removed during recycling. By taking out this specific layer, the substrate can be recovered clean without requiring complex chemical treatment processes, thus maintaining both simplicity and 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
The laminate provides excellent blocking resistance and scratch resistance while enabling efficient deinking of active energy ray curing type inks from non-absorbent substrates, improving recycling efficiency and reducing marine pollution.
Implementation Method 1
an anchor layer and an ink layer in this order on a non-absorbent substrate, wherein the anchor layer is a layer obtained by drying an aqueous anchor agent containing an aqueous resin
Implementation Method 2
the ink layer is a layer obtained by curing an active energy ray curing type ink with active energy rays
Data Source
AI summary
Provided is a laminate having an anchor layer and an ink layer in the stated order on a non-absorbent substrate, wherein the anchor layer includes an aqueous resin, the acid value of the aqueous resin is 25-300 mgKOH/g and the glass transition temperature thereof is 10-150°C, and the ink layer is a cured product of at least one ink selected from active energy ray-curable offset printing ink, active energy ray-curable flexographic printing ink, and active energy ray-curable resin letterpress printing ink.