Flexible Package Films with Layered Post-Industrial Recycled Content
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Solution Overview
Problem
Existing methods for recycling polymeric materials in flexible packages often result in reduced quality, limiting the use of recycled materials to low amounts due to adverse effects on mechanical and optical properties, processability, and sealing performance.
Innovation Solution
A method involving the use of post-industrial recycled material from precursor polymeric film, which is substantially the same as the final film, comprising at least 30-55% of the total weight, with inner layers containing higher recycled content than outer layers, to form flexible packages with enhanced tensile strength and elongation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If recycled materials are added back into the manufacturing process, then sustainability and environmental aspects are improved, but mechanical properties (tensile strength, elongation) and processability deteriorate
Solution Approach 1:
The patent applies local quality by creating a multi-layer film structure where different layers have different compositions and recycled material contents. The first and second outer layers contain lower amounts of recycled material to maintain surface quality, printing, and sealing properties, while the intermediate layer contains higher amounts of recycled material to achieve sustainability goals. This localized differentiation allows the package to meet both environmental and mechanical performance requirements.
2Object-affected harmful factors
If recycled materials are added back into the manufacturing process, then sustainability is improved, but optical properties and sealing performance deteriorate
Solution Approach 1:
The patent places layers with lower recycled material content (first and second outer layers) at the surfaces that require high optical quality for printing and visual appearance. The intermediate layer with higher recycled material content is positioned internally where it does not directly affect surface aesthetics. This strategic placement preserves optical and sealing performance while maximizing recycling utilization.
3Object-affected harmful factors
If high amounts of recycled material are used, then sustainability is improved, but film quality and processability deteriorate
Solution Approach 1:
The patent concentrates higher recycled material content in the intermediate layer away from the outer surfaces, where processability issues such as printing and sealing are most critical. The outer layers maintain lower recycled material content to ensure good processability during manufacturing operations. This spatial distribution allows high overall recycling rates while preserving manufacturing ease.
Data Source
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AI summary
Use of post-industrial recycled (PIR) material for a making flexible package made of polymeric film. The PIR material is formed of precursor polymeric film which is substantially the same as the polymeric film of the flexible package. The precursor polymeric film may be obtained from precursor flexible packaging. The invention also relates to a method of making a flexible packaging using PIR material formed of precursor polymeric film which is substantially the same as the polymeric film of the flexible package.