Microperforated Laminated Plastic Washing for Adhesive Removal

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Solution Overview

Problem

Existing methods for recycling laminated plastics are inefficient due to the difficulty in accessing and removing interlaminar adhesives and inks, which prevents effective separation and recycling of the plastic materials.

Innovation Solution

A method involving microperforation of laminated plastic materials using microneedles, followed by a washing process with alkaline aqueous solutions containing surfactants, and subsequent separation using centrifugation and decanting/hydrocyclones to facilitate the removal of adhesives and inks, allowing for effective recycling.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of substance

If laminated plastic materials are subjected to traditional mechanical/thermal separation or chemical treatment methods, then the plastic sheets can be detached, but the interlaminar adhesives and inks remain trapped within the plastic layers, preventing effective removal and recycling

Engineering Contradiction:

Improveremoval efficiency of adhesives and inksVSAvoidprocess complexity

Core Design Contradiction:

Loss of substanceVSDevice complexity

Solution Approach 1:

The invention applies segmentation by microperforating the plastic sheets into numerous small channels, dividing the continuous plastic matrix into segmented regions. This allows washing solutions to access previously unreachable interlaminar areas where adhesives and inks are trapped, enabling their effective removal while maintaining the overall sheet structure for recycling

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention uses washing solutions containing surfactants as intermediaries to facilitate the removal of adhesives and inks. These surfactant-containing solutions penetrate through the microperforations and act as mediators between the plastic substrate and the adhesives/inks, reducing surface tension and enabling effective cleaning without damaging the plastic layers

Inventive Principle:

Principle #24Intermediary (Mediator)

2Ease of operation

If the laminated material is ground to powder size to enable reagent access to the aluminium layer, then the aluminium can be removed, but the plastic material loses its structural integrity and requires extensive reprocessing

Engineering Contradiction:

Improveaccess to interlaminar areaVSAvoidstructural integrity of plastic sheets

Core Design Contradiction:

Ease of operationVSStrength

Solution Approach 1:

The invention applies local quality by creating microperforations only in specific locations where access to interlaminar adhesives is needed, rather than grinding the entire plastic sheet into powder. This localized modification maintains the overall structural integrity of the plastic sheets while providing sufficient access points for washing solutions to reach and remove adhesives and inks

Inventive Principle:

Principle #3Local quality

3Productivity

If high shear force is applied through stirring or rolling to detach sheets, then separation can be achieved, but the process requires extensive energy input and does not effectively remove trapped adhesives and inks

Engineering Contradiction:

Improveseparation efficiencyVSAvoidenergy consumption

Core Design Contradiction:

ProductivityVSUse of energy by moving object

Solution Approach 1:

The invention replaces the traditional mechanical separation system (high shear force through stirring or rolling) with a chemical-cleaning system. Instead of relying on mechanical force to detach and clean sheets, the method uses microperforations combined with surfactant-containing washing solutions to chemically access and remove adhesives and inks, significantly reducing energy consumption while improving separation efficiency

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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

Facilitates the separation and recycling of laminated plastics by enabling efficient access to interlaminar adhesives and inks, thereby optimizing the recycling process and reducing operational costs.

Implementation Method 1

microperforation of the laminated plastic material using microneedles

Methodology Applied

Scientific EffectMechanical Force: Mechanical Force

Implementation Method 2

removing the ink and adhesive by adding a washing solution

Methodology Applied

Scientific EffectSolvation: Solvation

Implementation Method 3

washing process with alkaline aqueous solutions containing surfactants

Methodology Applied

Scientific EffectSurfactant: Surfactant

Implementation Method 4

subsequent separation using centrifugation

Methodology Applied

Scientific EffectCentrifugal separation: Centrifugal Separation

Implementation Method 5

decanting/hydrocyclones to facilitate the removal of adhesives and inks

Methodology Applied

Scientific EffectCyclone separation: Cyclone Separation

Data Source

PatentEP4059686B1Method for removing adhesives and interlaminar inks on laminated plastic material

Publication Date: 2026.04.08 UNIV DE ALICANTE

Figure 1~2
Figure 3

AI summary

The present invention relates to a method for removing interlaminar adhesives and/or inks on laminated plastic material, which comprises the following steps: a) microperforating the laminated plastic material with at least one microperforation per cm2, b) removing the ink and/or adhesive by adding a washing solution to the microperforated plastic resulting from step a), c) separating the plastic material and the aqueous material.