WO1997003802A1 - Materiau d'emballage multicouche comprenant une couche de plastiques melanges recycles - Google Patents

Materiau d'emballage multicouche comprenant une couche de plastiques melanges recycles Download PDF

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Publication number
WO1997003802A1
WO1997003802A1 PCT/US1996/011324 US9611324W WO9703802A1 WO 1997003802 A1 WO1997003802 A1 WO 1997003802A1 US 9611324 W US9611324 W US 9611324W WO 9703802 A1 WO9703802 A1 WO 9703802A1
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WO
WIPO (PCT)
Prior art keywords
layer
packaging material
consumer
post
multilayer packaging
Prior art date
Application number
PCT/US1996/011324
Other languages
English (en)
Inventor
Peter Frisk
Ramin Heydarpour
Original Assignee
Tetra Laval Holdings & Finance S.A.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Tetra Laval Holdings & Finance S.A. filed Critical Tetra Laval Holdings & Finance S.A.
Priority to AU63459/96A priority Critical patent/AU6345996A/en
Publication of WO1997003802A1 publication Critical patent/WO1997003802A1/fr

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B27/08—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
    • B29B17/00—Recovery of plastics or other constituents of waste material containing plastics
    • B29B17/0026—Recovery of plastics or other constituents of waste material containing plastics by agglomeration or compacting
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
    • B29B17/00—Recovery of plastics or other constituents of waste material containing plastics
    • B29B17/02—Separating plastics from other materials
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
    • B29C48/07—Flat, e.g. panels
    • B29C48/08—Flat, e.g. panels flexible, e.g. films
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/16—Articles comprising two or more components, e.g. co-extruded layers
    • B29C48/18—Articles comprising two or more components, e.g. co-extruded layers the components being layers
    • B29C48/21—Articles comprising two or more components, e.g. co-extruded layers the components being layers the layers being joined at their surfaces
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25—Component parts, details or accessories; Auxiliary operations
    • B29C48/36—Means for plasticising or homogenising the moulding material or forcing it through the nozzle or die
    • B29C48/50—Details of extruders
    • B29C48/76—Venting, drying means; Degassing means
    • B29C48/765—Venting, drying means; Degassing means in the extruder apparatus
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/18—Layered products comprising a layer of synthetic resin characterised by the use of special additives
    • B32B27/20—Layered products comprising a layer of synthetic resin characterised by the use of special additives using fillers, pigments, thixotroping agents
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J11/00—Recovery or working-up of waste materials
    • C08J11/04—Recovery or working-up of waste materials of polymers
    • C08J11/06—Recovery or working-up of waste materials of polymers without chemical reactions
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
    • B29B17/00—Recovery of plastics or other constituents of waste material containing plastics
    • B29B17/02—Separating plastics from other materials
    • B29B2017/0213—Specific separating techniques
    • B29B2017/0293—Dissolving the materials in gases or liquids
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
    • B29B17/00—Recovery of plastics or other constituents of waste material containing plastics
    • B29B17/04—Disintegrating plastics, e.g. by milling
    • B29B2017/0424—Specific disintegrating techniques; devices therefor
    • B29B2017/046—Extruder as pressing tool with calibrated die openings for forming and disintegrating pasty or melted material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
    • B29C48/07—Flat, e.g. panels
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
    • B29C48/09—Articles with cross-sections having partially or fully enclosed cavities, e.g. pipes or channels
    • B29C48/10—Articles with cross-sections having partially or fully enclosed cavities, e.g. pipes or channels flexible, e.g. blown foils
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/16—Articles comprising two or more components, e.g. co-extruded layers
    • B29C48/17—Articles comprising two or more components, e.g. co-extruded layers the components having different colours
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2023/00—Use of polyalkenes or derivatives thereof as moulding material
    • B29K2023/04—Polymers of ethylene
    • B29K2023/06—PE, i.e. polyethylene
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2023/00—Use of polyalkenes or derivatives thereof as moulding material
    • B29K2023/04—Polymers of ethylene
    • B29K2023/08—Copolymers of ethylene
    • B29K2023/086—EVOH, i.e. ethylene vinyl alcohol copolymer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2023/00—Use of polyalkenes or derivatives thereof as moulding material
    • B29K2023/10—Polymers of propylene
    • B29K2023/12—PP, i.e. polypropylene
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2025/00—Use of polymers of vinyl-aromatic compounds or derivatives thereof as moulding material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2027/00—Use of polyvinylhalogenides or derivatives thereof as moulding material
    • B29K2027/06—PVC, i.e. polyvinylchloride
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2077/00—Use of PA, i.e. polyamides, e.g. polyesteramides or derivatives thereof, as moulding material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/06—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/26—Scrap or recycled material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2009/00—Layered products
    • B29L2009/005—Layered products coated
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/712—Containers; Packaging elements or accessories, Packages
    • B29L2031/7158—Bottles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/30—Properties of the layers or laminate having particular thermal properties
    • B32B2307/31—Heat sealable
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/40—Properties of the layers or laminate having particular optical properties
    • B32B2307/402—Coloured
    • B32B2307/4026—Coloured within the layer by addition of a colorant, e.g. pigments, dyes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/724—Permeability to gases, adsorption
    • B32B2307/7242—Non-permeable
    • B32B2307/7244—Oxygen barrier
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P20/00—Technologies relating to chemical industry
    • Y02P20/50—Improvements relating to the production of bulk chemicals
    • Y02P20/54—Improvements relating to the production of bulk chemicals using solvents, e.g. supercritical solvents or ionic liquids
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02W—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
    • Y02W30/00—Technologies for solid waste management
    • Y02W30/50—Reuse, recycling or recovery technologies
    • Y02W30/62—Plastics recycling; Rubber recycling
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02W—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
    • Y02W30/00—Technologies for solid waste management
    • Y02W30/50—Reuse, recycling or recovery technologies
    • Y02W30/80—Packaging reuse or recycling, e.g. of multilayer packaging

Definitions

  • the present invention relates to a multilayer packaging material that uses commingled post-consumer plastics in at least one layer of the multilayer structure.
  • Sorting segregates the various polymer containers from one another based on the polymer material from which the container is composed. Thus, a container composed only of polyethylene is segregated from the commingled plastics and placed with other polyethylene containers for re-processing. Sorting is a generally costly and inefficient process.
  • the post-consumer waste comprises commingled plastics, including, for example, a mix of containers of polyethylene, polypropylene, polyethylene teraphthalate, polystyrene, polyamide, and polyvinyl chloride usually with some level of contaminant materials, such as pigments, thermoset materials, fiberglass, talc and adhesives.
  • commingled plastics give mixtures with poor physical properties.
  • the post-consumer, commingled plastics waste material is generally viewed as being unfit for re-processing to form containers and often finds its way into landfills.
  • a multilayer packaging material which provides an economical and ecologically responsible use of post-consumer, commingled plastics is set forth.
  • the packaging material is formed as a multilayer material that comprises at least one layer formed from post-consumer, commingled plastics in such amount as to constitute either a fill material within the layer or a majority of the layer composition by weight.
  • the post-consumer, commingled plastics layer may be compatibilized. Compatibilization may take place through: 1) chemical compatibilization treatment of the post-consumer, commingled plastics layer; 2) the addition of a compatibilizing agent to the post-consumer, commingled plastics layer; and/or 3) mechanical compatibilization of the post-consumer, commingled plastics layer.
  • compatibilization allows the commingled plastics to form a layer with better physical properties than a similar uncompatibilized commingled plastics layer.
  • Additional polymer and structural substrate layers may be utilized depending on the particular use of the multilayer packaging material. Consumer appeal of the multilayer packaging material may be enhanced by using colorizing pigments in one or more of the polymer material layers, as well as in the post-consumer, commingled plastics layer.
  • An oxygen barrier layer may be utilized when the multilayer packaging material is used to store oxygen sensitive products. Tie layers may also be used to join otherwise incompatible layers to one another.
  • Fig. 1 is a cross-sectional elevation of one embodiment of the multilayer packaging material of the present invention.
  • Fig. 2 is a cross-sectional elevation of a further embodiment of the multilayer packaging material of the present invention which includes an exterior polymer layer.
  • Fig. 3 is a cross-sectional elevation of an embodiment of the multilayer packaging material of the present invention which includes an oxygen barrier layer disposed between the post-consumer, commingled plastics layer and the product contact layer.
  • Fig. 4 is a cross-sectional elevation of an embodiment of the multilayer packaging material of the present invention which includes an oxygen barrier layer and illustrates potential placement of tie layers within the multilayer structure.
  • Fig. 5 is a cross-sectional elevation of an embodiment of the multilayer packaging material of the present invention which illustrates the use of colorizing pigments within the material layers.
  • Fig. 6 is a cross-sectional elevation of the embodiment of FIG. 5 with the addition of an oxygen barrier layer and associated tie layers.
  • Fig. 7 is a cross-sectional elevation of an embodiment of the multilayer packaging material of the present invention illustrating the use of a structural substrate, such as paperboard, that assists in supporting a container formed from the packaging material.
  • Fig. 8 is a partial cross-sectional view of an extruder that has been modified to subject the post- consumer, commingled plastics to supercritical C0 2 as the plastics are extruded.
  • Multilayer packaging material 10 comprises a product contact layer 15 and a layer 20 of post-consumer, commingled plastics.
  • Contact layer 15 comprises a heat sealable polymer material, preferably a polyolefin material, and more preferably polyethylene.
  • Layer 20 comprises, for example, a post-consumer mixture of several of the following plastic materials: polyethylene, polypropylene, polyethylene teraphthalate, polystyrene, polyamide, and polyvinyl chloride usually with some level of contaminant materials, such as pigments, thermoset materials, fiberglass, talc and adhesives. It will be recognized that other post-consumer plastics mixtures may be utilized.
  • the particular composition of layer 20 depends on the composition of the post- consumer, commingled plastics waste from which it is formed. In some instances, choicer recyclables have been removed from the waste, and layer 20 is formed from the remaining commingled plastics material.
  • the layer 20 may comprise between about 50% to about 100%, by weight, of the post-consumer, commingled plastics.
  • the post-consumer, commingled plastics may be used as a fill material in layer 20 and may constitute less than 50% by weight of the material of layer 20.
  • the post-consumer, commingled plastic layer 20 may further comprise from, for example, about 1% to about 20% by weight of a dark pigment, for example, carbon black, to cover-up the raw color of the post-consumer material.
  • a dark pigment for example, carbon black
  • the raw color of the mixture may be unattractive due to the variety of pigmented materials of which the post-consumer material is typically composed.
  • Layer 20 may be formed in any of the manners disclosed here in connection with secondary recycling methods. Layer 20 and layer 15 may, for example, be coextruded with one another to form the multilayer material 10.
  • the post-consumer, commingled plastics layer 20 may optionally be compatibilized through one or more of the following processes: 1) chemical treatment of the post-consumer, commingled plastics; 2) addition of a compatibilizing agent to the post-consumer, commingled plastics; 3) mechanical compatibilization of the post-consumer, commingled plastics.
  • chemical treatment of the post-consumer, commingled plastics material fluorine, chlorine, oxygen gas, etc., may be used to oxidize the polymer materials of the commingled plastics. When oxidized, the interstitial regions between the polymer materials provide sites at which the materials may bond to one another thereby providing a more cohesive layer.
  • the post-consumer, commingled plastics layer 20 may include a compatibilizing agent of an ionomer, such as Surlyn ®, or a copolymer, such as ethylene acrylic acid (EAA) , etc.
  • a compatibilizing agent of an ionomer such as Surlyn ®, or a copolymer, such as ethylene acrylic acid (EAA) , etc.
  • EAA ethylene acrylic acid
  • the compatibilizing agent may also comprise polyethylene, polypropylene, or any mixture thereof.
  • Such readily available and inexpensive polymers are particularly well-suited for use in layer 20 when the post-consumer, commingled plastics of layer 20 are used as fill material.
  • the post-consumer, commingled plastics layer may be mechanically compatibilized using, for example, a pulverization process.
  • a pulverization process suitable for use in the present context is described in Enikolopyan, N. S., "Recycling of Materials by the Method of Elastic- Deformation Pulverization", Advances in Recovery and Recycling - Concepts and Technology, ISBN 87-89753-08-9 (1993) .
  • Enikolopyan, N. S. "Recycling of Materials by the Method of Elastic- Deformation Pulverization", Advances in Recovery and Recycling - Concepts and Technology, ISBN 87-89753-08-9 (1993) .
  • Post-consumer, commingled plastics layer 20 and contact layer 15 may be coextruded as a film in sheet or tubular form. If the multilayer material is extruded in a tubular form, then a package may be formed therefrom by transversely sealing the tube ends thereby creating a pouch-like package with layer 20 at the exterior and product contact layer 15 at the interior, as illustrated in FIG. 1.
  • Fig. 2 illustrates a further embodiment of a multilayer packaging material 30 which incorporates an external layer 35 of printable polymer material.
  • the packaging material 30 includes a post-consumer, commingled plastic layer 40 disposed between the exterior layer 35 and an interior, heat sealable product contact layer 45.
  • Exterior layer 35 preferably comprises a polyolefin film material and, more preferably, a polyolefin material film capable of having printing affixed thereto. Most preferably, it is formed from the same heat sealable material as product contact layer 45.
  • the three layers of Fig. 2 may be coextruded.
  • External layer 35 is preferably used when a substrate for printing is desired. This is because the variety of materials and contaminants present in the post-consumer, commingled plastics material generally prevent direct adhesion of the inks and dyes used for package printing.
  • External layer 35 may further comprise a pigment, such as carbon black or Ti0 2 to prevent the raw color of layer 40 from being seen from the exterior of the container.
  • the layers 35 and 45 may be formed from materials that are heat sealable to one another. In this manner, the multilayer packaging material 30 will be heat sealable exterior to exterior, exterior to interior, and interior to interior.
  • Fig. 3 illustrates a further embodiment of a multilayer packaging material 50 which is particularly well-suited for use in the containment of oxygen sensitive products.
  • the post-consumer, commingled plastics layer 55 is disposed between an exterior layer 60 and an oxygen barrier layer 65.
  • a product contact layer 70 is disposed interior to oxygen barrier layer 65.
  • Oxygen barrier layer 65 comprises any extrudable oxygen barrier material, for example, ethylene vinyl alcohol (EVOH) , polyvinyldichloride, polyester, polyamide, or other oxygen barrier materials.
  • EVOH ethylene vinyl alcohol
  • an adhesive tie layer 75 such as ethylene acrylic acid (EAA) or the like, between the oxygen barrier layer 65 and the post-consumer, commingled plastics layer 55 (see Fig. 4) .
  • an adhesive tie layer for example, at 80, may be used between any of the illustrated adjacent layers to facilitate a bond between such layers. Flame or corona treatment of one or more of the illustrated layers may likewise be employed to facilitate joining of dissimilar layers.
  • Packaging material structures having additives for enhancing the appearance of the materials are illustrated in exemplary form in Figs. 5 and 6 at 90 and 95, respectively.
  • a layer of post-consumer, commingled plastics 100 also includes carbon black as a colorizing material.
  • Layer 100 is disposed between opposed layers 105, 110 of, for example, polyethylene, each containing Ti0 2 as a colorizing agent. The Ti0 2 gives the polyethylene layers a white appearance.
  • a similarly colorized structure is illustrated in Fig. 6 wherein an exterior layer 115 of polyethylene and Ti0 2 is disposed exterior to a post- consumer, commingled plastics layer 120 having carbon black dispersed therein.
  • a sandwich layer of adhesive tie layer 125/oxygen barrier (e.g., EVOH) 130/ adhesive tie layer 135 is disposed between the layer 120 and an interior product contact layer 140 of, for example, polyethylene.
  • a flexible pouch or self- supporting structure may be formed using any of the foregoing layer sequences. Self-support of the resulting package may be enhanced by using any of the foregoing embodiments of the packaging material in conjunction with a structural substrate.
  • Fig. 7 illustrates one such multilayer packaging material 145 which incorporates a structural substrate 150, such as paperboard, which facilitates self-support of the packaging material.
  • the structural substrate 150 may render the material suitable for use, for example, in forming a self-supporting gable-top container.
  • the multilayer material comprises an exterior sealing layer 155, such as polyethylene, the structural substrate 160, an adhesive tie layer 165, such as EAA or the like, a post-consumer, commingled plastics layer 170, and a product contact layer 175.
  • the exterior sealing layer 155 and the product contact layer 175 may be made from heat sealable materials to render the packaging material 145 heat sealable interior to interior, exterior to interior, and exterior to exterior. It will be recognized that an adhesive tie layer may be used between any of the adjacent layers shown in Fig.
  • one or more oxygen barrier layers may be disposed in the packaging material, or, alternatively, omitted.
  • the product contact layer may be formed from an oxygen barrier material, or a separate oxygen barrier layer may be disposed as one of the layers between the structural substrate and the product contact layer.
  • An oxygen barrier material may also be dispersed in the post consumer, commingled plastic layer and, for example, may function as a compatibilizing agent.
  • the post- consumer, commingled plastics layer may be subject to treatment to remove and/or inactivate any undesirable chemicals present in the post-consumer mix. This can be done by extruding the layer in such a manner that the contaminants are removed. This can be achieved by heating or by a combined treatment with, for example, supercritical C0 2 .
  • a material layer may be interposed between the post- consumer, commingled plastics layer and the food product. The interposed layer should be formed form a material that provides a barrier against migration of the contaminants from the commingled plastics layer and the food product.
  • Fig. 8 shows one embodiment of an extruder 180 modified to treat the post-consumer, commingled waste using a supercritical C0 2 process.
  • the extruder 180 includes a hopper 185 containing the post- consumer, commingled plastics waste.
  • the waste has been washed in a solvent to assist in removing unwanted contaminants from the plastics.
  • the extruder 180 further includes a first passage 190 that communicates supercritical C0 2 to the interstitial region 195 between an extruder barrel 200 and an extruder screw 205 to place the supercritical C0 2 in contact with the commingled plastics as they pass through the extruder barrel 200.
  • the supercritical C0 2 may then be allowed to exit a second passage 210 from the interstitial region 195.
  • the supercritical C0 2 functions as a solvent and assists in removing unwanted contaminants from the post- consumer, commingled plastics. Such removal facilitates use of the resulting multilayer packaging material in food containers. It will be recognized that other configurations for introducing supercritical C ⁇ 2 to the commingled plastics may likewise be employed.
  • the foregoing multilayer packaging material structures provide packages which efficiently use what has heretofore been deemed waste materials. These material structures are thus environmentally friendly since they reduce the amount of plastic waste at, for example, landfills. Additionally, these material structures are economical since post-consumer, commingled plastics are generally readily available and inexpensive. While particular elements, embodiments and applications of the present invention have been shown and described, it will be understood, of course, that the invention is not limited thereto since modifications may be made by those skilled in the art, particularly in light of the foregoing teachings. It is therefore contemplated by the appended claims to cover such modifications as incorporate those features which come within the spirit and scope of the invention.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Environmental & Geological Engineering (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Health & Medical Sciences (AREA)
  • Sustainable Development (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Medicinal Chemistry (AREA)
  • Polymers & Plastics (AREA)
  • Organic Chemistry (AREA)
  • Laminated Bodies (AREA)
  • Wrappers (AREA)

Abstract

Matériau d'emballage multicouche comportant des matériaux recyclés non triés, constitué d'une couche de contact (70) en polyoléfine et d'une couche de plastiques mélangés recyclés (55), pouvant comporter également une couche d'étanchéité (65). Les plastiques mélangés sont rendus compatibles chimiquement ou mécaniquement, et peuvent être purifiés au moyen de dioxyde de carbone à l'état de fluide supercritique.
PCT/US1996/011324 1995-07-14 1996-07-03 Materiau d'emballage multicouche comprenant une couche de plastiques melanges recycles WO1997003802A1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
AU63459/96A AU6345996A (en) 1995-07-14 1996-07-03 Multilayer packaging material incorporating a layer of post-consumer, commingled plastics

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US50237095A 1995-07-14 1995-07-14
US08/502,370 1995-07-14

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WO1997003802A1 true WO1997003802A1 (fr) 1997-02-06

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Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0838318A2 (fr) * 1996-10-25 1998-04-29 Praxair Technology, Inc. Procédé pour éliminer des contaminants des matières polymériques
WO2004052619A1 (fr) * 2002-12-12 2004-06-24 Rapra Technology Limited Procede d'extrusion
WO2017037260A1 (fr) * 2015-09-03 2017-03-09 Centre National De La Recherche Scientifique Procede et dispositif de demontage de systemes multicouches comprenant au moins un composant organique
US11649098B1 (en) * 2019-10-02 2023-05-16 Printpack Illinois, Inc. Food storage containers formed at least partially from post-consumer recycled polymeric material

Citations (7)

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Publication number Priority date Publication date Assignee Title
US4493806A (en) * 1981-05-29 1985-01-15 Christopher Hatzikelis Recycling of contaminated plastic
US4647509A (en) * 1985-10-07 1987-03-03 The Dow Chemical Company Thermoformable multilayer barrier structures
US4940612A (en) * 1988-05-09 1990-07-10 International Paper Company Oxygen impermeable leak free container
US5073203A (en) * 1989-11-08 1991-12-17 Cobarr Spa Method for recycling polyethylene terephthalate (PET) beverage bottles by treating with carbon dioxide
US5128196A (en) * 1990-03-16 1992-07-07 Amoco Corporation Foamed core-reclaim multi-layer sheet and process for production thereof
US5237048A (en) * 1988-09-22 1993-08-17 Toyo Engineering Corporation Method for purifying polymer
US5432231A (en) * 1993-07-06 1995-07-11 Mobil Oil Corporation Recycling stretch wrap film

Patent Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4493806A (en) * 1981-05-29 1985-01-15 Christopher Hatzikelis Recycling of contaminated plastic
US4647509A (en) * 1985-10-07 1987-03-03 The Dow Chemical Company Thermoformable multilayer barrier structures
US4940612A (en) * 1988-05-09 1990-07-10 International Paper Company Oxygen impermeable leak free container
US5237048A (en) * 1988-09-22 1993-08-17 Toyo Engineering Corporation Method for purifying polymer
US5073203A (en) * 1989-11-08 1991-12-17 Cobarr Spa Method for recycling polyethylene terephthalate (PET) beverage bottles by treating with carbon dioxide
US5128196A (en) * 1990-03-16 1992-07-07 Amoco Corporation Foamed core-reclaim multi-layer sheet and process for production thereof
US5432231A (en) * 1993-07-06 1995-07-11 Mobil Oil Corporation Recycling stretch wrap film

Cited By (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0838318A2 (fr) * 1996-10-25 1998-04-29 Praxair Technology, Inc. Procédé pour éliminer des contaminants des matières polymériques
EP0838318A3 (fr) * 1996-10-25 2000-04-19 Praxair Technology, Inc. Procédé pour éliminer des contaminants des matières polymériques
WO2004052619A1 (fr) * 2002-12-12 2004-06-24 Rapra Technology Limited Procede d'extrusion
WO2017037260A1 (fr) * 2015-09-03 2017-03-09 Centre National De La Recherche Scientifique Procede et dispositif de demontage de systemes multicouches comprenant au moins un composant organique
FR3040704A1 (fr) * 2015-09-03 2017-03-10 Centre Nat Rech Scient Procede et dispositif de demontage de systemes multicouches comprenant au moins un composant organique
US10507597B2 (en) 2015-09-03 2019-12-17 Centre National De La Recherche Scientifique Method and device for dismantling multilayer systems including at least one organic component
RU2722104C2 (ru) * 2015-09-03 2020-05-26 Сантр Насьональ Де Ля Решерш Сьентифик Способ и устройство для разъединения многослойных систем, содержащих по меньшей мере один органический компонент
US11649098B1 (en) * 2019-10-02 2023-05-16 Printpack Illinois, Inc. Food storage containers formed at least partially from post-consumer recycled polymeric material

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