PCR Flexible Tube Containers With Cast Multilayer Printable Walls
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Solution Overview
Problem
Existing methods fail to produce multi-layer polymeric materials for flexible tube containers with high PCR content due to surface defects from recycled plastic contaminants, making them unsuitable for printing and aesthetically unacceptable.
Innovation Solution
A manufacturing process involving a pushing action towards the interior of the sheet, such as casting or calendering, is used to produce a multi-layer polymeric material with a virgin polyolefin outermost layer, hiding PCR layer imperfections and ensuring a smooth surface suitable for printing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If blown film process is used to produce multi-layer polymeric material with high PCR content, then recyclability is improved, but surface quality deteriorates due to roughness and fisheye defects
Solution Approach 1:
The multi-layer polymeric material is divided into distinct layers: an outermost virgin polyolefin layer providing smooth surface quality for printing, inner layers containing PCR material providing recyclability, and barrier layers providing functional properties. This segmentation allows each layer to fulfill its specific function without compromising the others.
Solution Approach 2:
Barrier layers made of EVOH or other barrier materials are inserted between the virgin polyolefin outermost layer and the PCR-containing inner layers. These intermediary layers prevent the diffusion of substances while allowing the structure to maintain both smooth surface quality and high recyclability content.
2Adaptability or versatility
If PCR material is incorporated into multi-layer polymeric material, then environmental sustainability is improved, but surface defects increase due to contaminants from recycled plastic
Solution Approach 1:
The harmful surface defects and contaminants from PCR material are extracted and isolated from the outermost layer by placing the virgin polyolefin layer on the exterior. This separates the functional requirement for smooth surface quality from the recyclability requirement, allowing the inner PCR layers to contain the contaminants while the outer layer provides defect-free surface.
Solution Approach 2:
The invention uses composite multi-layer structures combining virgin polyolefin, barrier layers, and PCR-containing layers. This composite structure leverages the advantages of each material: the smoothness of virgin polyolefin for printing, the barrier properties of EVOH layers, and the recyclability of PCR material, while the layered configuration prevents contamination from affecting the surface quality.
3Manufacturing precision
If outermost layer is made of virgin polyolefin to ensure smooth surface, then printability is improved, but PCR content proportion decreases
Solution Approach 1:
The total material thickness is segmented into multiple layers, with the outermost virgin polyolefin layer occupying only a small portion (e.g., 10-30 micrometers). The remaining thickness is distributed across barrier layers and PCR-containing layers, enabling high overall PCR content while maintaining a thin smooth surface layer for printing.
Solution Approach 2:
Instead of increasing the thickness of the outermost layer to improve printability, the invention adds the barrier layer dimension between the outermost layer and the PCR-containing layers. This dimensional addition allows the outermost layer to remain thin for printing while the barrier layer provides the necessary functional properties and the inner layers provide recyclability.
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 process results in a high-quality, printable surface that hides PCR defects, allowing for high PCR content while meeting cosmetic segment aesthetic requirements.
Implementation Method 1
The pushing action, for example by rolls, involves, as a result, a smooth surface. Indeed, the particles of the PCR layer are pushed towards in the interior of the sheet and covered with the virgin PE outermost layer.
Implementation Method 2
the step of pushing action towards the interior of the sheet is obtained by casting process or calendering process. In other words, advantageously, the multi-layer polymeric material is produced as a cast sheet or a calendered sheet.
Data Source
AI summary
A flexible tube container comprising a side wall formed from a multi-layer polymeric material, the side wall comprising a longitudinal weld or join, the multi-layer polymeric material comprising a thickness of between 200 and 400 micrometers, said multi-layer polymeric material comprising at least one layer of virgin polyolefin based and at least one layer of post-consumer resin or recycled material, wherein the multi-layer polymeric material is produced with a step of pushing action towards the interior of the sheet with no subsequent extrusion or lamination step, and the layer of virgin polyolefin is an outermost layer.