Multilayer Recycled Plastic Film Coextrusion
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Solution Overview
Problem
Current recycling methods for plastic waste struggle to produce high-performance virgin plastics entirely from recycled materials, often requiring significant amounts of virgin plastics and resulting in products with inferior properties and limited recyclability, leading to environmental and economic inefficiencies.
Innovation Solution
A multilayer plastic film composed of at least three interconnected film layers with a plastic recyclate content of at least 80% by weight, formed through coextrusion, which maintains equivalent or superior mechanical, optical, and haptic properties to primary plastic films, enabling efficient recycling and reuse.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If plastic waste is recycled using conventional methods, then the quantity of waste is reduced, but the mechanical properties and performance of the resulting plastic are inferior to virgin plastic
Solution Approach 1:
The patent applies composite materials by combining recycled plastic particles with virgin plastic matrix to create a composite material that achieves both waste reduction and maintained mechanical properties. The composite structure allows the virgin plastic to provide structural integrity while the recycled particles contribute to volume reduction and sustainability.
Solution Approach 2:
The patent employs parameter changes by modifying the composition ratio between recycled plastic particles and virgin plastic matrix, as well as adjusting processing parameters such as extrusion temperature and injection parameters, to optimize both the mechanical properties and the recycled content proportion of the final product.
2Strength
If high proportions of virgin plastic are used to compensate for inferior recycled plastic properties, then mechanical performance is improved, but the recyclability and environmental benefits are reduced
Solution Approach 1:
The patent uses parameter changes to optimize the proportion of recycled plastic particles in the composite material, finding the optimal balance between mechanical performance and recyclability. By controlling the particle size, shape, and concentration parameters, the patent achieves satisfactory mechanical properties while maintaining high recyclability of the final product.
3Quantity of substance
If recycled plastic is used to produce new plastic products, then raw material consumption is reduced, but the resulting products have limited recyclability
Solution Approach 1:
The patent applies composite materials by creating a structured combination of recycled plastic particles embedded in a virgin plastic matrix, which maintains the overall recyclability of the product. The composite structure is designed so that the material can be processed again through conventional recycling methods, extending the recyclability cycle while reducing raw material consumption.
4Strength
If multilayer structures are used to improve film properties, then mechanical and optical properties are enhanced, but the manufacturing complexity increases
Solution Approach 1:
The patent applies segmentation by dividing the plastic film into multiple layers with different functions: one layer contains the recycled plastic particles while other layers provide structural support and optical properties. This segmentation allows each layer to be optimized independently, improving overall film performance while managing manufacturing complexity through specialized extrusion heads for each layer.
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 multilayer plastic film achieves high performance and recyclability, reducing waste generation, conserving raw materials, and sustaining an economic cycle while maintaining comparable properties to primary plastic films, thus addressing the limitations of existing recycling technologies.
Implementation Method 1
formed through coextrusion
Data Source
AI summary
The invention relates to a multilayer plastic film, in particular a multilayer plastic composite film, preferably a multilayer plastic packaging film, based on plastic recyclate (recycled plastic), in particular based on plastic recyclate originating from waste, with a plastic recyclate content of at least 80% by weight, based on the plastic film, and to its use, in particular as packaging material. The plastic recyclate is preferably post-consumer plastic recyclate (PCR plastic recyclate), in particular PCR recycled films.