Polymeric Film Extrusion for Printable Packaging with High Recycled Content
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for recycling polymeric materials into flexible packages face challenges such as reduced mechanical properties, optical quality, and processability, limiting the use of recycled materials to low percentages due to adverse effects on film quality.
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, combined with virgin material to form a polymeric film, allowing for high percentages of recycled content without compromising mechanical strength and printability, by extruding and converting the film into flexible packages.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If recycled materials are added to the manufacturing process, then environmental sustainability is improved, but mechanical properties and optical quality deteriorate
Solution Approach 1:
The patent segments the polymeric film into multiple layers with different compositions and recycled material percentages. The first layer contains a higher proportion of recycled material (30-100%) while the second layer contains a lower proportion (0-70%), allowing each layer to be optimized for its specific function while maintaining overall package performance
Solution Approach 2:
Different layers of the polymeric film are assigned different local qualities regarding recycled material content. The outer layer (first layer) that contacts the product is designed with higher recycled content for sustainability, while the inner layer (second layer) has lower recycled content to ensure proper sealing and mechanical performance
2Object-affected harmful factors
If recycled materials are added to the manufacturing process, then environmental sustainability is improved, but optical properties deteriorate
Solution Approach 1:
The patent segments the polymeric film into multiple layers with different compositions and recycled material percentages. The first layer contains a higher proportion of recycled material (30-100%) while the second layer contains a lower proportion (0-70%), allowing each layer to be optimized for its specific function while maintaining overall package performance
Solution Approach 2:
Different layers of the polymeric film are assigned different local qualities regarding recycled material content. The outer layer (first layer) that contacts the product is designed with higher recycled content for sustainability, while the inner layer (second layer) has lower recycled content to ensure proper sealing and mechanical performance
3Object-affected harmful factors
If recycled materials are added to the manufacturing process, then environmental sustainability is improved, but processability deteriorates
Solution Approach 1:
The patent segments the polymeric film into multiple layers with different compositions and recycled material percentages. The first layer contains a higher proportion of recycled material (30-100%) while the second layer contains a lower proportion (0-70%), allowing each layer to be optimized for its specific function while maintaining overall package performance
Solution Approach 2:
Different layers of the polymeric film are assigned different local qualities regarding recycled material content. The outer layer (first layer) that contacts the product is designed with higher recycled content for sustainability, while the inner layer (second layer) has lower recycled content to ensure proper sealing and mechanical performance
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 enables the use of at least 30-55% post-industrial recycled material in polymeric films, maintaining or improving tensile strength and elongation at break, while ensuring printability and sealability, thus addressing environmental concerns and enhancing sustainability.
Implementation Method 1
e) extruding the molten polymeric material and molten post-industrial recycled material to form a polymeric film
Implementation Method 2
first areas of the first outer layer may be sealed to second areas of the first outer layer to form seams
Data Source
AI summary
A method of making a flexible package made of polymeric film is provided. The method comprises the steps of: a) obtaining post-industrial recycled material from post-industrial recycling of precursor polymeric film formed of precursor polymeric material which is substantially the same as the virgin polymeric material of step c), b) providing at least 30 weight-% post-industrial recycled material obtained in step a) based on the overall weight of the polymeric film, c) providing up to 70 weight-% of virgin polymeric material based on the total weight of the polymeric film, and d) jointly melting the virgin polymeric material and the post-industrial recycled material. The method comprises the steps of: e) extruding the molten polymeric material and molten post-industrial recycled material to form a polymeric film, f) providing print on one or both surfaces of the polymeric film, and g) converting the polymeric film into the flexible package.