De-inking Plastic Containers Using Organic Solvents
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Solution Overview
Problem
Current methods for removing ink from plastic materials are often hazardous, time-consuming, and inefficient, leading to significant scrap production during printing line startups, which is costly due to rising raw material prices.
Innovation Solution
A method and apparatus that uses a non-toxic, environmentally friendly organic solvent to solvate and remove ink from plastic surfaces, followed by a water wash cycle and drying process, allowing for efficient and automated de-inking of plastic articles without hazardous chemicals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional hazardous chemical methods are used to remove ink from plastic materials, then ink removal effectiveness is improved, but safety and environmental friendliness deteriorate
Solution Approach 1:
The patent changes the chemical parameters of the de-inking solution by using food-grade, non-toxic organic solvents (such as ethanol, isopropanol, or acetone) instead of traditional hazardous chemicals. This parameter substitution maintains ink removal effectiveness while eliminating safety and environmental hazards, directly resolving the contradiction between manufacturing precision and harmful factors.
2Adaptability or versatility
If manual adjustments and traditional printing operations are used, then printing flexibility is maintained, but scrap production increases
Solution Approach 1:
The patent implements a de-inking system that recovers previously discarded plastic materials by removing printed ink, allowing these materials to be reused in subsequent printing operations. This recovery process converts waste scrap into reusable resources, reducing substance loss while maintaining printing flexibility through automated handling.
Solution Approach 2:
The patent creates a continuous de-inking and re-printing cycle where plastic materials that would traditionally be discarded as scrap are instead continuously processed through automated de-inking systems and fed back into production. This continuous operation eliminates interruptions and reduces waste, resolving the contradiction between adaptability and substance loss.
3Manufacturing precision
If multiple de-inking stations are used to ensure complete ink removal, then de-inking effectiveness is improved, but device complexity increases
Solution Approach 1:
The patent combines multiple de-inking functions (solvent application, mechanical scrubbing, rinsing, and drying) into an integrated automated system where components work in sequence within a unified processing line. This merging approach achieves complete ink removal through coordinated actions while avoiding the complexity of separate, standalone stations for each function.
Solution Approach 2:
The patent designs processing stations that perform multiple functions simultaneously - for example, a single station that applies solvent, scrubs the surface, and begins rinsing in one integrated unit. This multi-functionality reduces the total number of stations needed while maintaining comprehensive de-inking effectiveness, resolving the contradiction between manufacturing precision and device complexity.
4Quantity of substance
If hazardous chemicals are used for ink removal, then ink solvating power is improved, but operational safety deteriorates
Solution Approach 1:
The patent uses food-grade organic solvents that are inherently safe, non-toxic, and environmentally friendly, replacing hazardous chemicals with safer alternatives that can be handled without special protective measures. These solvents maintain adequate ink solvating capability while eliminating operational safety risks, directly resolving the contradiction between substance effectiveness and safety.
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 method effectively recycles plastic articles by removing ink without hazardous chemicals, reducing waste and operational time, making the process safe, bio-friendly, and cost-effective.
Implementation Method 1
a solvent application station that applies organic solvent to the synthetic resin material, where the organic solvent is capable of solvating the ink image
Data Source
AI summary
Apparatus and method for removing an ink image from a plastic substrate, particularly a plastic container such as a cup, are provided. A solvent capable of solvating the ink image is utilized in order to de-ink articles so that they can be recycled and re-imprinted thereby reducing waste associated with printing line start up. As the articles may be intended for use with food and beverage products, a safe and non-toxic solvent may be selected. However, to ensure that the article is not contaminated with foreign materials prior to human use, the de-inked article may undergo a rinse and drying operation to remove solvent residues and UV light treatment to eliminate any harmful microorganisms that may be present on the article's surfaces.