Chemically Recycled Polyolefin Print Substrate for Defect-Free Packaging

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Solution Overview

Problem

Conventional packaging materials using recycled resins, particularly those containing contaminants, suffer from issues such as surface asperities and defective print appearances due to foreign matter, leading to missing characters and uneven print quality, especially in low dot density printed layers.

Innovation Solution

Utilizing a chemically recycled resin in the substrate, which is produced through processes like gasification or depolymerization to convert discarded resin into monomers and then polymerize them, reducing contamination by impurities and aggregates, and avoiding heat treatments that cause thermal degradation, thereby minimizing surface protrusions and asperities.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Quantity of substance

If mechanically recycled resin is used in the substrate, then the recycled resin content can be increased to achieve environmental sustainability, but foreign matter such as impurities, gels, and aggregates appears on the surface, causing asperities that prevent ink adhesion and result in defective print appearances with missing characters

Engineering Contradiction:

Improverecycled resin contentVSAvoidprint appearance quality

Core Design Contradiction:

Quantity of substanceVSManufacturing precision

Solution Approach 1:

The patent changes the recycling method parameter from mechanical recycling to chemical recycling. This parameter change fundamentally alters the surface quality of the recycled resin, eliminating foreign matter and asperities while maintaining high recycled resin content, thereby resolving the contradiction between sustainability and print quality

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent replaces the mechanical recycling system with a chemical recycling system. Instead of mechanically cleaning and crushing resin products, the invention uses chemical processes (gasification, liquefaction, depolymerization) to convert discarded resin into monomers and then polymerize them, eliminating the source of surface defects

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Ease of manufacture

If mechanically recycled resin is used, then production costs can be reduced by utilizing post-consumer resin, but thermal degradation occurs during heat treatment processes, creating surface protrusions and asperities that compromise print quality

Engineering Contradiction:

Improveproduction costVSAvoidsurface smoothness

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The patent replaces thermal/chemical heat treatment processes with chemical recycling processes. Instead of heating and melting recycled resin which causes thermal degradation, the invention uses chemical conversion (gasification, liquefaction, depolymerization) followed by polymerization, eliminating thermal damage while maintaining cost-effectiveness

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent converts the harmful effect of thermal degradation into a beneficial process. The heat treatment that previously caused asperities and defects is replaced by controlled chemical processes that actually improve the molecular structure and surface quality of the recycled resin

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

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 use of chemically recycled resin in packaging materials ensures a good print appearance with reduced defects, even at high recycled resin content, while maintaining laminate strength and gas barrier performance, thus enhancing the quality of printed layers.

Implementation Method 1

a process of converting discarded resin into monomers, by gasification or liquefaction

Methodology Applied

Scientific EffectGasification:

Implementation Method 2

a process of converting discarded resin into monomers, by gasification or liquefaction

Methodology Applied

Scientific EffectLiquefaction:

Implementation Method 3

a process of converting discarded resin into monomers, by depolymerization

Methodology Applied

Scientific EffectDepolymerization:

Implementation Method 4

subsequent refining into naphtha, or a process of converting discarded resin into monomers, by depolymerization, and then polymerizing the monomers

Methodology Applied

Scientific EffectPolymerization: Photopolymerisation

Implementation Method 5

unlike mechanically recycled resin, chemically recycled resin is not subjected to heat treatments such as heating and melting after the recycling process, which allows it to be less susceptible to thermal degradation

Methodology Applied

Scientific EffectThermal degradation:

Data Source

PatentUS20260054904A1Print substrate, packaging material laminate, packaging container, and packaged article

Publication Date: 2026.02.26 TOPPAN HOLDINGS INC

AI summary

The print substrate includes a substrate and a printed layer formed thereon. The substrate is a polyolefin resin film containing recycled resin, and the recycled resin is a chemically recycled resin. A packaging material laminate includes the print substrate and a sealing layer.