Multi-Layer Coated Recycled Paper Stock for High-Fidelity Printing
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Solution Overview
Problem
Existing paper stock products made from recycled fibers lack sufficient strength and are not fully recyclable, limiting their use and environmental sustainability.
Innovation Solution
A multi-layered paper stock product composed of 100% recycled fibers, adhered with adhesive layers and coated with compatible materials for printing, allowing for high print fidelity and minimal VOC emissions, and optionally including a magnetic stripe for machine-readability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If recycled paper stock is used to create paper products, then environmental sustainability is improved, but the strength and quality of the paper product deteriorates
Solution Approach 1:
The patent applies composite materials by combining multiple layers of recycled paper with adhesive layers and coating layers. The composite structure includes at least two paper layers made from recycled fibers, bonded together using adhesives, and coated with polymer or latex-based coating materials to enhance strength, surface quality, and printability. This multi-layer composite approach allows the paper product to achieve both environmental sustainability through recycled materials and improved mechanical strength through the adhesive and coating components.
2Ease of operation
If traditional coating materials are used on recycled paper, then printability is improved, but volatile organic compound emissions increase
Solution Approach 1:
The patent applies parameter changes by modifying the chemical composition and physical properties of coating materials. Specifically, the patent uses water-based or solvent-free coating formulations that eliminate or reduce volatile organic compounds while maintaining adequate printability. The coating layer comprises polymer or latex-based materials with adjusted viscosity, drying characteristics, and adhesion properties to enable successful printing without relying on traditional solvent-based coatings that emit VOCs.
3Strength
If multiple layers are added to improve paper strength, then product quality is improved, but manufacturing complexity increases
Solution Approach 1:
The patent applies segmentation by dividing the paper product into distinct functional layers: at least two paper layers made from recycled fibers for structural integrity, adhesive layers for bonding, and coating layers for surface quality and printability. Each layer is optimized for its specific function and can be manufactured and applied using established industrial processes. The segmented structure allows for modular assembly and simplifies quality control by addressing each layer's requirements independently.
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 product achieves plastic-like performance, multi-platform printability, and full recyclability, while reducing volatile organic compound emissions, and can replace plastic products in various applications.
Implementation Method 1
one or more adhesive layers disposed between the at least two paper layers
Implementation Method 2
at least one coating layer disposed over at least one of the at least two paper layers and including: a first coating material; and a second coating material of differing material composition from the first coating material
Data Source
AI summary
A coated, recycled paper stock product and related manufacturing techniques are disclosed. In accordance with some embodiments, the disclosed product may include a plurality of constituent paper layers which have been adhered together by a corresponding quantity of interstitial adhesive layers. Any one (or all) of such constituent paper layers may be made from 100% (wt %) recycled fiber, in accordance with some embodiments. Optionally, the disclosed product further may include one or more coating layers on a given constituent paper layer. In accordance with some embodiments, either (or both) of the outermost paper layers may include a coating layer disposed over the external surface (e.g., printable side) thereof. In this manner, a laminated paper product may be provided having coating(s) (or otherwise being treated with one or more treatments of a physical and/or chemical nature) for printing on multiple printing platforms, in accordance with some embodiments.