Patent 11961422

Derivative works

Defensive disclosure: derivative variations of each claim designed to render future incremental improvements obvious or non-novel.

Active provider: Google · gemini-2.5-flash

Derivative works

Defensive disclosure: derivative variations of each claim designed to render future incremental improvements obvious or non-novel.

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Defensive Disclosure: Expanding Prior Art for US Patent 11961422

This document describes derivative variations of US Patent 11961422, intended for defensive publishing to establish prior art and render future incremental improvements obvious or non-novel. The analysis focuses on extending the patent's core concepts across various technical axes.

Derivatives of Independent Claim 1: Recyclable Shrink Label

Claim 1 broadly covers a recyclable shrink label with a heat shrink film and a light blocking layer, designed to block at least 80% of incident light from 200 nm to 900 nm.

1.1. Material & Component Substitution

Derivative 1.1.1: Bio-Derived & Biodegradable Heat Shrink Film with Nanoparticle Light Blocking Layer

  • Enabling Description: A recyclable shrink label comprises a heat shrink film manufactured from a bio-derived and compostable polymer blend, such as polyhydroxyalkanoates (PHA) co-blended with polylactic acid (PLA) at a 70:30 ratio to achieve desired shrink properties (e.g., 40-60% TD shrinkage at 90°C). The first surface of this film is coated with a light blocking layer consisting of a polymer matrix (e.g., an aqueous acrylic dispersion) embedded with dispersed graphene oxide nanoparticles at a concentration of 0.5-2.0 wt% (relative to the dry film weight of the layer), functionalized with broad-spectrum UV-Vis-NIR absorbing chromophores (e.g., phthalocyanines or porphyrins). This layer is applied via gravure printing to achieve a dry film thickness of 1-3 µm. The graphene oxide nanoparticles, ranging in size from 50-500 nm, provide broad-spectrum attenuation, blocking at least 95% of incident light from 200 nm to 1000 nm. The entire label is designed for industrial composting, with the film breaking down within 180 days under ASTM D6400 conditions, and the light blocking layer components being non-ecotoxic.
graph TD
    A[Bio-derived PHA/PLA Heat Shrink Film] -- First Surface --> B[Graphene Oxide Nanoparticle Light Blocking Layer (Phthalocyanine functionalized)]
    B -- Outer Surface --> C[Indicia Layer (Compostable Ink)]
    C -- Optional --> D[High Opacity Layer (Calcium Carbonate)]
    style A fill:#e6ffed,stroke:#333,stroke-width:2px
    style B fill:#cceeff,stroke:#333,stroke-width:2px
    style C fill:#fffacd,stroke:#333,stroke-width:2px
    style D fill:#ffddcc,stroke:#333,stroke-width:2px

1.2. Operational Parameter Expansion

Derivative 1.2.1: Ultra-High Shrinkage, Cryogenic-Compatible Label for Liquid Gas Containers

  • Enabling Description: A recyclable shrink label is designed for cryogenic containers, such as those holding liquid nitrogen or oxygen, requiring application at room temperature and subsequent operation down to -196°C. The heat shrink film is a multi-layered co-extrusion of specialty polyolefin elastomer (POE) and cross-linked linear low-density polyethylene (LLDPE), achieving a transverse direction (TD) shrinkage of 85-95% when heated to 80°C (for application) and maintaining integrity and adhesion at -196°C. The film has a thickness of 20 µm. The light blocking layer, adjacent the first surface, consists of a solvent-based polyimide resin binder (stable at cryogenic temperatures) with embedded vacuum-deposited aluminum flakes (particle size 0.05-0.5 µm) at a dry coat weight of 5 ppr, providing an effective light blocking rate of >99.5% from 200 nm to 1100 nm. The label's adhesive is a cryogenic-grade, pressure-sensitive acrylic adhesive.
graph LR
    A[Cryogenic Container]
    B[Heat Shrink Film (POE/XL-LLDPE, 20µm)]
    C[Light Blocking Layer (Polyimide/Al Flakes)]
    D[Indicia Layer (Cryo-stable Ink)]
    E[Protective Topcoat (Fluoropolymer)]
    A -- Applied To --> B
    B -- Inner Surface Bonded To --> C
    C -- Outer Surface Applied To --> D
    D -- Covered By --> E
    style A fill:#a9d18e,stroke:#333,stroke-width:2px
    style B fill:#fcf8e3,stroke:#333,stroke-width:2px
    style C fill:#cceeff,stroke:#333,stroke-width:2px
    style D fill:#fffacd,stroke:#333,stroke-width:2px
    style E fill:#e0e0e0,stroke:#333,stroke-width:2px

1.3. Cross-Domain Application

Derivative 1.3.1: Light-Blocking Shrink Sleeves for Aerospace Composite Curing

  • Enabling Description: A recyclable light-blocking shrink label is adapted for use in aerospace manufacturing, specifically as a temporary protective and shaping sleeve during the curing of UV-sensitive composite structures (e.g., carbon fiber reinforced polymers with UV-curable resins). The heat shrink film is a high-temperature resistant polyester (e.g., PET-PEN blend) with a controlled shrinkage of 10-20% at 150°C, ensuring uniform pressure application during autoclave curing. The film thickness is 50 µm. The light blocking layer, applied to the inner surface of the sleeve, comprises a ceramic pigment (e.g., Yttrium Aluminum Garnet, YAG) dispersed in a silicone elastomer binder, applied at a dry coat weight of 10 ppr. This layer provides thermal stability up to 250°C and blocks >99% of UV-Vis light (200-700 nm) to prevent premature or uneven curing, while remaining easily peelable post-cure for recycling.
graph TD
    A[Raw Composite Structure]
    B[Recyclable Shrink Sleeve]
    C[Heat Shrink Film (PET-PEN, 50µm)]
    D[Light Blocking Layer (YAG/Silicone)]
    E[Autoclave Curing Process]
    F[Cured Composite Structure]
    A -- Encased By --> B
    B --> C
    C -- Inner Layer --> D
    B -- Subjected To --> E
    E -- Results In --> F
    F -- Label Removed & Recycled --> G[Recycling Stream]
    style A fill:#add8e6,stroke:#333,stroke-width:2px
    style B fill:#d8bfd8,stroke:#333,stroke-width:2px
    style C fill:#ffe4e1,stroke:#333,stroke-width:2px
    style D fill:#ccffcc,stroke:#333,stroke-width:2px
    style E fill:#ffc0cb,stroke:#333,stroke-width:2px
    style F fill:#90ee90,stroke:#333,stroke-width:2px
    style G fill:#f0e68c,stroke:#333,stroke-width:2px

1.4. Integration with Emerging Tech

Derivative 1.4.1: AI-Optimized, IoT-Monitored Smart Shrink Label

  • Enabling Description: A recyclable shrink label integrates IoT sensors and AI-driven optimization. The heat shrink film is a PET-G composition (60 µm thick, 50% TD shrink at 90°C). The light blocking layer comprises a variable density silver nanoparticle ink, whose application thickness and concentration are dynamically adjusted by an AI algorithm during printing. This AI monitors real-time spectrophotometric feedback from the label and container surface, ensuring minimum silver usage while achieving 99.9% light blocking (200-900 nm) across variable container geometries and product sensitivities. The label incorporates embedded, ultra-thin, flexible NFC/RFID tags (e.g., printed electronics) that serve as IoT sensors. These tags monitor label integrity (e.g., presence of tears, delamination via impedance change) and temperature exposure, transmitting data to a blockchain ledger for immutable supply chain verification. The data includes label material provenance, print parameters, and environmental conditions during transit, enhancing traceability and optimizing recycling processes by flagging compromised labels.
graph TD
    A[AI Printing Control Unit] -- Optimizes Parameters --> B[Silver Nanoparticle Ink Deposition]
    C[PET-G Heat Shrink Film] -- Receives Ink --> B
    D[NFC/RFID IoT Sensor] -- Embedded In --> C
    B -- Forms --> E[Light Blocking Layer]
    E -- Applied To --> F[Container]
    D -- Monitors Integrity/Temp --> G[Cloud IoT Platform]
    G -- Records Data --> H[Blockchain Ledger]
    H -- Verifies --> I[Supply Chain]
    style A fill:#a9d18e,stroke:#333,stroke-width:2px
    style B fill:#ffe4e1,stroke:#333,stroke-width:2px
    style C fill:#fcf8e3,stroke:#333,stroke-width:2px
    style D fill:#d8bfd8,stroke:#333,stroke-width:2px
    style E fill:#cceeff,stroke:#333,stroke-width:2px
    style F fill:#add8e6,stroke:#333,stroke-width:2px
    style G fill:#ffddcc,stroke:#333,stroke-width:2px
    style H fill:#90ee90,stroke:#333,stroke-width:2px
    style I fill:#f0e68c,stroke:#333,stroke-width:2px

1.5. The "Inverse" or Failure Mode

Derivative 1.5.1: Chemically Triggered Delaminating Shrink Label for Controlled Removal

  • Enabling Description: A recyclable shrink label is designed for controlled delamination and removal under specific chemical conditions, enabling efficient material separation in closed-loop recycling. The heat shrink film is a PET co-polymer (e.g., PETG, 45 µm, 60% TD shrink at 95°C). The light blocking layer comprises carbon black pigment (2.0 ppr) in a binder resin that is designed to lose adhesion and become water-soluble upon exposure to a mildly acidic aqueous solution (pH 4.0-5.0) at 40°C. This "failure" mode is intentional; when immersed in the recycling pre-wash acid bath, the light blocking layer, along with any indicia inks, delaminates cleanly from the PETG film within 5 minutes, allowing for separate recovery of the clear PETG film and the concentrated pigment sludge. This process is engineered to occur without staining the primary container.
stateDiagram-v2
    state "Label Applied to Container" as Applied
    state "Initiate Recycling Process" as Recycling
    state "Acid Bath Exposure (pH 4-5, 40C)" as AcidBath
    state "Delamination/Solubilization of LB Layer" as Delamination
    state "Clear Film Recovery" as FilmRecovery
    state "Pigment Sludge Separation" as SludgeSeparation

    Applied --> Recycling: End-of-Life
    Recycling --> AcidBath: Submerge
    AcidBath --> Delamination: Chemical Reaction
    Delamination --> FilmRecovery: Film Separates
    Delamination --> SludgeSeparation: Pigments Recovered
    FilmRecovery --> [*]
    SludgeSeparation --> [*]
    state Applied {
        LightBlockingLayer : Adhered
        IndiciaLayer : Adhered
    }
    state Delamination {
        LightBlockingLayer : Soluble/Dispersed
        IndiciaLayer : Removed
    }
    style Applied fill:#f9f,stroke:#333,stroke-width:2px
    style Recycling fill:#ccf,stroke:#333,stroke-width:2px
    style AcidBath fill:#cff,stroke:#333,stroke-width:2px
    style Delamination fill:#ffc,stroke:#333,stroke-width:2px
    style FilmRecovery fill:#afa,stroke:#333,stroke-width:2px
    style SludgeSeparation fill:#faa,stroke:#333,stroke-width:2px

Derivatives of Independent Claim 17: Article

Claim 17 describes an article comprising a container and the recyclable shrink label from Claim 1, with the label's first surface facing the container.

2.1. Material & Component Substitution

Derivative 2.1.1: Multi-Material Container with Integrated Recycled Content Label

  • Enabling Description: An article comprises a container manufactured from a novel bi-layer composite: an inner layer of food-grade recycled HDPE (rHDPE) and an outer structural layer of lignin-based bioplastic. The recyclable shrink label, as per Claim 1, is specifically adapted for adhesion to the lignin-based outer surface. The label's heat shrink film is composed of post-consumer recycled PET (rPET), and its light blocking layer uses a mineral-based pigment (e.g., ground basalt dust, 1-10 µm particle size) suspended in a water-based acrylic binder. The entire label is engineered to contain at least 75% recycled content by weight. The label's internal surface is coated with a lignin-compatible, water-soluble adhesive, ensuring clean separation from the container during a hot caustic wash, allowing both container layers and the label to be processed through separate but compatible recycling streams.
graph TD
    A[Container]
    B[Inner Layer (rHDPE)]
    C[Outer Layer (Lignin Bioplastic)]
    D[Recyclable Shrink Label]
    E[rPET Heat Shrink Film]
    F[Mineral-based Light Blocking Layer]
    G[Water-soluble Lignin-Compatible Adhesive]
    A -- Comprises --> B
    A -- Comprises --> C
    C -- Adheres To --> D
    D -- Comprises --> E
    E -- Has --> F
    F -- Adheres to C via --> G
    style A fill:#a9d18e,stroke:#333,stroke-width:2px
    style B fill:#ffe4e1,stroke:#333,stroke-width:2px
    style C fill:#fcf8e3,stroke:#333,stroke-width:2px
    style D fill:#cceeff,stroke:#333,stroke-width:2px
    style E fill:#fffacd,stroke:#333,stroke-width:2px
    style F fill:#d8bfd8,stroke:#333,stroke-width:2px
    style G fill:#ccffcc,stroke:#333,stroke-width:2px

2.2. Operational Parameter Expansion

Derivative 2.2.1: High-Pressure Resistant Article with Integrated Structural Light-Blocking Label

  • Enabling Description: An article comprises a pressure vessel container (e.g., for high-pressure medical gases or industrial aerosols) constructed from a filament-wound composite of carbon fiber and epoxy resin, rated for internal pressures up to 300 bar. The recyclable shrink label is specifically engineered to function as an integral, structural component that reinforces the container while providing light blocking. The heat shrink film is a high-tensile strength aramid polymer (e.g., Kevlar-reinforced PET) with a thickness of 150 µm and radial shrink properties (20% TD at 180°C) that actively compress the filament winding during application, enhancing structural integrity. The light blocking layer, adjacent the first surface, consists of a dense, chemically inert ceramic-polymer composite (e.g., zirconium dioxide nanoparticles in a fluoropolymer binder) applied at a dry film weight of 20 ppr, blocking >99.9% of light from 200 nm to 1200 nm, and also providing abrasion and chemical resistance to the underlying composite.
graph TD
    A[Pressure Vessel Container (Carbon Fiber/Epoxy)] -- External Surface --> B[Recyclable Shrink Label (Aramid-PET)]
    B -- Comprises --> C[Heat Shrink Film (Aramid-PET, 150µm)]
    C -- First Surface Layer --> D[Light Blocking Layer (ZrO2/Fluoropolymer)]
    D -- Functions As --> E[Structural Reinforcement]
    E -- Provides --> F[Light Blocking (>99.9% 200-1200nm)]
    style A fill:#e6ffed,stroke:#333,stroke-width:2px
    style B fill:#cceeff,stroke:#333,stroke-width:2px
    style C fill:#fffacd,stroke:#333,stroke-width:2px
    style D fill:#ffddcc,stroke:#333,stroke-width:2px
    style E fill:#add8e6,stroke:#333,stroke-width:2px
    style F fill:#d8bfd8,stroke:#333,stroke-width:2px

2.3. Cross-Domain Application

Derivative 2.3.1: Pharmaceutical Vial with Trackable, UV-Protective Shrink Label

  • Enabling Description: An article comprises a pharmaceutical vial made of clear borosilicate glass, containing light-sensitive injectable drugs. The recyclable shrink label is tailored for this application. The heat shrink film is a pharmaceutical-grade, low-extractable PETG film (30 µm, 70% TD shrink at 85°C), ensuring no leaching into the drug product. The light blocking layer comprises a non-migratory, biocompatible titanium dioxide pigment (average particle size 0.2 µm) dispersed in a UV-curable acrylic binder, applied directly to the inner surface of the label at 1.5 ppr. This layer blocks >98% of UV-Vis light (200-500 nm), crucial for drug stability. The label further includes a serialization code (e.g., 2D DataMatrix) printed with a tamper-evident ink, enabling individual vial tracking and authentication within the pharmaceutical supply chain. The label is designed to float off during a standard glass recycling caustic wash.
graph TD
    A[Pharmaceutical Vial (Borosilicate Glass)] -- Holds --> B[Light-Sensitive Drug]
    A -- Covered By --> C[Recyclable Shrink Label]
    C -- Comprises --> D[PETG Heat Shrink Film]
    D -- Inner Layer --> E[Light Blocking Layer (TiO2/Acrylic)]
    E -- Prevents Degradation Of --> B
    C -- Includes --> F[Serialization Code (2D DataMatrix)]
    F -- Ensures --> G[Authentication & Tracking]
    style A fill:#a9d18e,stroke:#333,stroke-width:2px
    style B fill:#ffe4e1,stroke:#333,stroke-width:2px
    style C fill:#fcf8e3,stroke:#333,stroke-width:2px
    style D fill:#cceeff,stroke:#333,stroke-width:2px
    style E fill:#fffacd,stroke:#333,stroke-width:2px
    style F fill:#d8bfd8,stroke:#333,stroke-width:2px
    style G fill:#ccffcc,stroke:#333,stroke-width:2px

2.4. Integration with Emerging Tech

Derivative 2.4.1: Bio-feedback Smart Container for Perishable Goods with AI-Managed Label

  • Enabling Description: An article consists of a container for perishable food items (e.g., probiotics, fresh produce), made of clear, oxygen-permeable PLA. The recyclable shrink label incorporates flexible, printed electrochemical biosensors that detect specific spoilage indicators (e.g., volatile organic compounds, pH changes) from the container's headspace. The heat shrink film is a PLA-based film (40 µm, 50% TD shrink at 70°C). The light blocking layer uses a photochromic pigment integrated into the polymer matrix. An onboard micro-controller, powered by a thin-film battery embedded in the label, receives data from the biosensors. An AI algorithm processes this bio-feedback to dynamically adjust the opacity of the photochromic light blocking layer (e.g., darkening when spoilage is detected or UV exposure is too high) to optimize product shelf life. This state change is visible to the consumer and signals a "use-by" status. The label's end-of-life status and material composition are recorded on a distributed ledger via an integrated NFC chip.
graph TD
    A[PLA Container] -- Contains --> B[Perishable Food]
    C[Recyclable Shrink Label] -- Applied To --> A
    C -- Includes --> D[Printed Electrochemical Biosensors]
    D -- Detects Spoilage --> E[Onboard Micro-controller (AI)]
    E -- Controls --> F[Photochromic Light Blocking Layer]
    F -- Changes Opacity --> G[Consumer Visual Feedback]
    C -- Integrates --> H[NFC Chip]
    H -- Records Data To --> I[Distributed Ledger]
    style A fill:#e6ffed,stroke:#333,stroke-width:2px
    style B fill:#ffe4e1,stroke:#333,stroke-width:2px
    style C fill:#cceeff,stroke:#333,stroke-width:2px
    style D fill:#fffacd,stroke:#333,stroke-width:2px
    style E fill:#ffddcc,stroke:#333,stroke-width:2px
    style F fill:#add8e6,stroke:#333,stroke-width:2px
    style G fill:#d8bfd8,stroke:#333,stroke-width:2px
    style H fill:#ccffcc,stroke:#333,stroke-width:2px
    style I fill:#f0e68c,stroke:#333,stroke-width:2px

2.5. The "Inverse" or Failure Mode

Derivative 2.5.1: Container with Dissolvable Label for Emergency Content Access

  • Enabling Description: An article comprises a container for emergency rations or medical supplies, requiring rapid access in critical situations. The container is a rigid, water-resistant HDPE bottle. The recyclable shrink label is designed for quick, controlled dissolution on demand. The heat shrink film is a water-soluble polyvinyl alcohol (PVOH) film (25 µm, 65% TD shrink at 80°C). The light blocking layer consists of a non-toxic, edible carbon black dispersion in a starch-based binder, blocking >90% of light (200-900 nm). In an emergency, exposure to water (e.g., rain, immersion) causes the PVOH film and starch binder to dissolve rapidly (within 30 seconds to 2 minutes), releasing the container from the label and allowing immediate access to its contents. The dissolved label components are environmentally benign.
stateDiagram-v2
    state "Label Applied to Container" as Applied
    state "Emergency Situation Detected" as Emergency
    state "Water Exposure" as WaterExposure
    state "PVOH Film Dissolution" as FilmDissolution
    state "Label Detached" as Detached
    state "Container Contents Accessible" as Accessible
    state "Environmentally Benign Dissolutes" as Dissolutes

    Applied --> Emergency: Event
    Emergency --> WaterExposure: Trigger
    WaterExposure --> FilmDissolution: Initiates
    FilmDissolution --> Detached: Label Breaks Down
    Detached --> Accessible: Container Free
    FilmDissolution --> Dissolutes: Components Disperse

    state Applied {
        PVOHFilm : Intact
        LightBlockingLayer : Adhered
    }
    state FilmDissolution {
        PVOHFilm : Dissolving
        LightBlockingLayer : Dispersing
    }
    style Applied fill:#f9f,stroke:#333,stroke-width:2px
    style Emergency fill:#ffc,stroke:#333,stroke-width:2px
    style WaterExposure fill:#cff,stroke:#333,stroke-width:2px
    style FilmDissolution fill:#afa,stroke:#333,stroke-width:2px
    style Detached fill:#faa,stroke:#333,stroke-width:2px
    style Accessible fill:#ccf,stroke:#333,stroke-width:2px
    style Dissolutes fill:#ffc0cb,stroke:#333,stroke-width:2px

Derivatives of Independent Claim 22: Method of Making a Label

Claim 22 describes a method for making a label, involving depositing an indicia layer, optionally a high opacity layer, and a light blocking composition.

3.1. Material & Component Substitution

Derivative 3.1.1: Additive Manufacturing (3D Printing) Method for Multi-Layer Labels

  • Enabling Description: A method of making a label for a container employs additive manufacturing (3D printing) techniques. The heat shrinkable film is formed by selective laser sintering (SLS) of a fine polymer powder (e.g., crystalline PET micro-pellets, 10-50 µm diameter) onto a tensioned substrate, creating a layer with controlled anisotropy for specific shrink characteristics (e.g., 60% TD shrink at 100°C). An indicia layer is then deposited using multi-jet fusion (MJF) technology, where photopolymerizable inks (with integrated colorants) are selectively jetted and fused onto the film. Subsequently, a high opacity layer, comprising a calcium carbonate nanofiller (50-200 nm particles) in a UV-curable resin, is jetted and cured. Finally, the light blocking composition, consisting of precisely aligned metallic nanoparticles (e.g., silver nanowires, aspect ratio 1:50-1:100) suspended in a volatile organic solvent-free carrier, is deposited via aerosol jet printing onto the high opacity layer. The aerosol jet process allows for controlled orientation of the nanowires to maximize light reflection and absorption, achieving >99% light blocking (200-900 nm) with minimal material usage.
graph TD
    A[Tensioned Substrate] -- SLS PET Powder --> B[Heat Shrinkable Film (3D Printed)]
    B -- MJF Photopolymer Inks --> C[Indicia Layer (3D Printed)]
    C -- Jetting Calcium Carbonate Nanofiller --> D[High Opacity Layer (3D Printed)]
    D -- Aerosol Jet Printing Silver Nanowires --> E[Light Blocking Layer (3D Printed)]
    E -- Results In --> F[Recyclable Shrink Label]
    style A fill:#e6ffed,stroke:#333,stroke-width:2px
    style B fill:#cceeff,stroke:#333,stroke-width:2px
    style C fill:#fffacd,stroke:#333,stroke-width:2px
    style D fill:#ffddcc,stroke:#333,stroke-width:2px
    style E fill:#add8e6,stroke:#333,stroke-width:2px
    style F fill:#d8bfd8,stroke:#333,stroke-width:2px

3.2. Operational Parameter Expansion

Derivative 3.2.1: Ultrafast, Low-Temperature Plasma-Enhanced Vapor Deposition Method

  • Enabling Description: A method of making a label for a container operates at extremely high speeds and low temperatures, minimizing energy consumption and substrate stress. A heat shrinkable film (e.g., 20 µm thin PET, designed for 70% TD shrink at 70°C) is continuously unwound in a vacuum chamber. An indicia layer is applied using a pulsed laser deposition (PLD) system, where pre-sintered ceramic pigment targets are ablated and deposited as thin, high-resolution graphic patterns. Subsequently, a light blocking composition is deposited using plasma-enhanced chemical vapor deposition (PECVD) at a substrate temperature of 50°C. This layer comprises an amorphous carbon film doped with silicon (Si-DLC), grown to a thickness of 50-100 nm. The PECVD process allows for precise control of film density and composition, resulting in a light blocking layer that achieves >99.8% attenuation across 200-1500 nm, significantly exceeding the patent's wavelength range. The process throughput is >500 meters per minute.
graph TD
    A[PET Film Unwind] --> B[Vacuum Chamber]
    B -- Pulsed Laser Deposition --> C[Indicia Layer Applied (Ceramic Pigment)]
    C -- PECVD (50°C) --> D[Light Blocking Layer Applied (Si-DLC, 50-100nm)]
    D --> E[Film Rewind]
    E -- Results In --> F[Recyclable Shrink Label Roll]
    style A fill:#e6ffed,stroke:#333,stroke-width:2px
    style B fill:#cceeff,stroke:#333,stroke-width:2px
    style C fill:#fffacd,stroke:#333,stroke-width:2px
    style D fill:#ffddcc,stroke:#333,stroke-width:2px
    style E fill:#add8e6,stroke:#333,stroke-width:2px
    style F fill:#d8bfd8,stroke:#333,stroke-width:2px

3.3. Cross-Domain Application

Derivative 3.3.1: Electronic Circuit Board Substrate with Integrated Photonic Light-Blocking Layers

  • Enabling Description: A method for fabricating a flexible electronic circuit board with integrated light-blocking properties. A heat shrinkable polyimide film (e.g., Kapton®, 125 µm thick) is used as the substrate, capable of controlled, anisotropic shrinkage for subsequent component alignment. An indicia layer (e.g., circuit traces, component identifiers) is deposited using direct-write copper ink (nanoparticle-based) with subsequent sintering to form conductive pathways. A light blocking composition is then deposited via roll-to-roll atomic layer deposition (ALD) of alternating layers of high and low refractive index metal oxides (e.g., TiO2/Al2O3) to form a photonic crystal structure with a bandgap tuned to block specific wavelengths (e.g., ambient light from 400-700 nm for sensitive optical components) at >99.9% efficiency. This ALD process creates a highly conformal, robust light blocking layer suitable for protecting embedded optical sensors or light-sensitive semiconductors on the flexible board.
graph TD
    A[Polyimide Film (Flexible Substrate)] -- Direct-Write Copper Ink --> B[Indicia Layer (Circuit Traces)]
    B -- Roll-to-Roll ALD --> C[Light Blocking Layer (TiO2/Al2O3 Photonic Crystal)]
    C -- Results In --> D[Flexible Circuit Board with Integrated Light Blocking]
    style A fill:#e6ffed,stroke:#333,stroke-width:2px
    style B fill:#cceeff,stroke:#333,stroke-width:2px
    style C fill:#fffacd,stroke:#333,stroke-width:2px
    style D fill:#ffddcc,stroke:#333,stroke-width:2px

3.4. Integration with Emerging Tech

Derivative 3.4.1: Robot-Assisted, AI-Vision Controlled Label Production with Blockchain Traceability

  • Enabling Description: A method of making a label for a container employs robotic systems guided by AI-vision for precision and quality control, with full process traceability on a blockchain. A robotic arm deposits an indicia layer using a high-precision inkjet printing head onto a dynamically positioned heat shrinkable film (e.g., PET, 50 µm). AI-powered vision systems continuously monitor print quality, registration, and color accuracy in real-time, adjusting print parameters (e.g., droplet size, nozzle pressure) to compensate for any film distortions or environmental fluctuations. A second robotic station applies a light blocking composition, using electrohydrodynamic (EHD) jet printing of a metallic nanoparticle ink, with AI-vision ensuring layer uniformity and desired optical density. All manufacturing data—raw material batch IDs, sensor readings (temperature, humidity), AI adjustments, print logs, and quality inspection results—are automatically hashed and timestamped onto a permissioned blockchain, providing an immutable record of each label's production. This ensures verifiable provenance and quality for recyclable materials.
graph TD
    A[Heat Shrink Film Supply] --> B{Robotic Arm 1 (Inkjet Print Head)}
    B -- Deposits Indicia Layer --> C[Label Substrate with Indicia]
    C --> D{AI Vision System 1}
    D -- Feedback Loop --> B
    C --> E{Robotic Arm 2 (EHD Jet Print Head)}
    E -- Deposits Light Blocking Comp. --> F[Label Substrate with LB Layer]
    F --> G{AI Vision System 2}
    G -- Feedback Loop --> E
    H[Process Data] --> I[Blockchain Network]
    F -- Generates --> H
    A,B,C,D,E,F,G -- All Data to --> I
    style A fill:#e6ffed,stroke:#333,stroke-width:2px
    style B fill:#cceeff,stroke:#333,stroke-width:2px
    style C fill:#fffacd,stroke:#333,stroke-width:2px
    style D fill:#ffddcc,stroke:#333,stroke-width:2px
    style E fill:#add8e6,stroke:#333,stroke-width:2px
    style F fill:#d8bfd8,stroke:#333,stroke-width:2px
    style G fill:#ccffcc,stroke:#333,stroke-width:2px
    style H fill:#f0e68c,stroke:#333,stroke-width:2px
    style I fill:#90ee90,stroke:#333,stroke-width:2px

3.5. The "Inverse" or Failure Mode

Derivative 3.5.1: Fail-Safe Production of Low-Opacity "Inspection Grade" Labels

  • Enabling Description: A method of making labels includes a controlled "failure" mode to produce labels with intentionally reduced light blocking for quality inspection or limited-use applications. When raw material parameters (e.g., pigment concentration in the light blocking composition) or process conditions (e.g., gravure cylinder cell volume) deviate outside a predefined tolerance for full opacity, an automated system diverts the production to a "low-opacity" mode. In this mode, the light blocking composition (e.g., a carbon black dispersion) is applied at a reduced dry coat weight (e.g., 0.1-0.2 ppr instead of 1.0 ppr), or with a coarser line screen (e.g., 50 LPI instead of 200 LPI), resulting in a label that blocks 50-70% of incident light (200-900 nm). These "inspection grade" labels are clearly marked and segregated, allowing internal quality checks of underlying film or indicia layers without full light blocking, while still being recyclable. This prevents waste of materials in cases where full light blocking is not achieved but the label is still functional for other purposes.
flowchart TD
    Start --> CheckMaterialSpecs{Material Specs OK?}
    CheckMaterialSpecs -- No --> ReducedLightBlockingMode
    CheckMaterialSpecs -- Yes --> FullLightBlockingMode
    FullLightBlockingMode --> ApplyIndiciaFull[Apply Indicia Layer (Standard)]
    FullLightBlockingMode --> ApplyLightBlockingFull[Apply Light Blocking Composition (Target Opacity)]
    ReducedLightBlockingMode --> ApplyIndiciaReduced[Apply Indicia Layer (Standard)]
    ReducedLightBlockingMode --> ApplyLightBlockingReduced[Apply Light Blocking Composition (Reduced Opacity)]
    ApplyLightBlockingFull --> MarkFull[Mark as Full Opacity Label]
    ApplyLightBlockingReduced --> MarkReduced[Mark as Low Opacity Label (Inspection Grade)]
    MarkFull --> End
    MarkReduced --> End
    style ReducedLightBlockingMode fill:#ffc,stroke:#333,stroke-width:2px
    style FullLightBlockingMode fill:#afa,stroke:#333,stroke-width:2px
    style MarkReduced fill:#faa,stroke:#333,stroke-width:2px
    style MarkFull fill:#add8e6,stroke:#333,stroke-width:2px

Derivatives of Independent Claim 23: Method of Recycling an Article

Claim 23 describes a method for recycling an article, involving determining PET composition, directing to a PET stream, and washing to remove inks/pigments.

4.1. Material & Component Substitution

Derivative 4.1.1: Enzymatic De-labeling and Bio-flotation Recycling for Mixed Bioplastic Articles

  • Enabling Description: A method of recycling an article, comprising a container (e.g., bio-PE) and a recyclable shrink label (e.g., PLA film with a cellulose-based light blocking layer), involves an enzymatic de-labeling step. After initial sorting, articles are introduced into a bioreactor containing a tailored enzyme cocktail (e.g., cutinases for PLA hydrolysis, cellulases for cellulose degradation) specifically designed to selectively break down the label's film and light blocking binder components at mild temperatures (30-45°C, pH 6.0-7.5). The liberated light blocking pigments (e.g., bio-carbon black, derived from pyrolysis of agricultural waste) are then separated from the container material (bio-PE) using a bio-flotation process, where the hydrophobic bio-PE floats, and the hydrophilic pigment particles sink, or vice versa, depending on surface functionalization. The remaining clean bio-PE flakes are then directed into a dedicated bioplastic recycling stream. This method avoids harsh chemicals and high temperatures, reducing energy consumption and enabling closed-loop recycling of bio-derived packaging.
graph TD
    A[Mixed Bioplastic Article (Container + Label)] --> B[Initial Sorting (NIR for Bioplastic ID)]
    B --> C[Enzyme Bioreactor (Cutinases, Cellulases)]
    C -- Digests Label Film/Binder --> D[Liberated Pigments + Container Material]
    D --> E[Bio-Flotation Separation]
    E -- Bio-PE Floats --> F[Clean Bio-PE Flakes]
    E -- Pigments Sink --> G[Recovered Pigment Sludge]
    F --> H[Bio-PE Recycling Stream]
    style A fill:#e6ffed,stroke:#333,stroke-width:2px
    style B fill:#cceeff,stroke:#333,stroke-width:2px
    style C fill:#fffacd,stroke:#333,stroke-width:2px
    style D fill:#ffddcc,stroke:#333,stroke-width:2px
    style E fill:#add8e6,stroke:#333,stroke-width:2px
    style F fill:#d8bfd8,stroke:#333,stroke-width:2px
    style G fill:#ccffcc,stroke:#333,stroke-width:2px
    style H fill:#f0e68c,stroke:#333,stroke-width:2px

4.2. Operational Parameter Expansion

Derivative 4.2.1: Supercritical CO2 Extraction for Zero-Waste De-coating

  • Enabling Description: A method of recycling an article, particularly valuable for sensitive or high-purity material recovery, utilizes supercritical carbon dioxide (scCO2) extraction for de-coating. After initial identification of a PET container with a light-blocking PET label, the article is chopped into flakes (5-10 mm). These flakes are introduced into a high-pressure vessel where scCO2 (e.g., 35°C, 200 bar) acts as a solvent to selectively dissolve and extract the ink resins and light blocking components (e.g., aluminum particles and polymeric binders) from the PET surfaces. The scCO2 with dissolved contaminants is then depressurized, causing the inks and pigments to precipitate while the CO2 is recycled. This process is highly efficient, leaves no solvent residues, and prevents staining, resulting in ultra-clean PET flakes suitable for closed-loop food-grade applications. The light blocking components are recovered as a concentrated solid, enabling their potential reuse or safe disposal.
graph TD
    A[PET Article (Container + Label)] --> B[Chopping into Flakes]
    B --> C[High-Pressure Vessel (scCO2, 35C, 200bar)]
    C -- Dissolves Inks/Pigments --> D[scCO2 + Contaminants]
    D --> E[Depressurization]
    E -- CO2 Recycled --> F[Clean scCO2]
    E -- Contaminants Precipitate --> G[Recovered Ink/Pigment Concentrate]
    C --> H[Clean PET Flakes]
    H --> I[High-Purity PET Recycling Stream]
    style A fill:#e6ffed,stroke:#333,stroke-width:2px
    style B fill:#cceeff,stroke:#333,stroke-width:2px
    style C fill:#fffacd,stroke:#333,stroke-width:2px
    style D fill:#ffddcc,stroke:#333,stroke-width:2px
    style E fill:#add8e6,stroke:#333,stroke-width:2px
    style F fill:#d8bfd8,stroke:#333,stroke-width:2px
    style G fill:#ccffcc,stroke:#333,stroke-width:2px
    style H fill:#f0e68c,stroke:#333,stroke-width:2px
    style I fill:#90ee90,stroke:#333,stroke-width:2px

4.3. Cross-Domain Application

Derivative 4.3.1: Automated Surgical Instrument Decontamination and Material Recovery

  • Enabling Description: A method for recycling, adapted for surgical instruments. The "article" comprises a reusable surgical instrument (e.g., stainless steel or PEEK polymer) with a temporary, light-blocking sterilization indicator label. The "recyclable shrink label" (here, a temporary indicator sleeve) is made of a bio-degradable polymer with a heat-sensitive light-blocking layer that changes color or transparency to indicate sterilization status. The method involves an automated system that first uses an optical scanner to identify the instrument type and label status. Instruments are then directed into a specialized wash chamber that employs cavitation ultrasound in a neutral enzymatic cleaning solution (pH 7.0, 50°C) to gently and completely detach the label and wash off the indicator pigments. The separated label materials are captured by microfiltration for safe disposal, while the clean, de-labeled instruments are transferred for re-sterilization. This ensures the integrity of the instrument material for reuse and prevents cross-contamination.
graph TD
    A[Surgical Instrument with Indicator Label] --> B[Automated Optical Scanner]
    B -- Identifies Instrument & Label Status --> C[Divert to Wash Chamber]
    C --> D[Cavitation Ultrasound + Enzymatic Solution]
    D -- Detaches Label & Cleans Instrument --> E[Clean, De-labeled Instrument]
    D --> F[Washing Solution with Label Material]
    F --> G[Microfiltration]
    G --> H[Captured Label Waste]
    E --> I[Re-sterilization Stream]
    style A fill:#e6ffed,stroke:#333,stroke-width:2px
    style B fill:#cceeff,stroke:#333,stroke-width:2px
    style C fill:#fffacd,stroke:#333,stroke-width:2px
    style D fill:#ffddcc,stroke:#333,stroke-width:2px
    style E fill:#add8e6,stroke:#333,stroke-width:2px
    style F fill:#d8bfd8,stroke:#333,stroke-width:2px
    style G fill:#ccffcc,stroke:#333,stroke-width:2px
    style H fill:#f0e68c,stroke:#333,stroke-width:2px
    style I fill:#90ee90,stroke:#333,stroke-width:2px

4.4. Integration with Emerging Tech

Derivative 4.4.1: AI-Driven Robotic Sorting and IoT-Monitored Caustic Wash for Complex Articles

  • Enabling Description: A method of recycling an article, especially effective for complex articles containing multiple material types (e.g., a PET container with a light-blocking label and a multi-polymer closure), integrates AI-driven robotic sorting with IoT-monitored washing. The articles are fed onto a conveyor system. AI-powered robotic arms equipped with hyperspectral imaging and NIR sensors precisely identify each component (PET container, PET label, different closure polymers) and their composition (e.g., presence of light blocking pigments). Based on this real-time data, the robots autonomously disassemble the article, separating the PET container and label from other components. The separated PET components are then directed into an IoT-enabled caustic wash bath, where embedded sensors monitor pH, temperature, and contaminant levels (e.g., dissolved ink concentrations, light blocking component dispersion). An AI system analyzes this IoT data to optimize wash parameters (e.g., detergent concentration, wash time, agitation intensity) to ensure complete removal of inks and pigments while minimizing chemical usage and energy consumption. All process data is logged to a distributed ledger for verifiable recycling chain integrity.
graph TD
    A[Complex Article Feed] --> B{AI Robotic Sorting}
    B -- Hyperspectral/NIR Sensor Data --> C[AI Control System]
    C -- Directs Robotic Arms --> B
    B -- Separates --> D[PET Container & Label]
    B -- Separates --> E[Other Components]
    D --> F[IoT-Enabled Caustic Wash Bath]
    F -- Sensor Data (pH, Temp, Contaminants) --> C
    C -- Optimizes Wash Params --> F
    F -- Washed --> G[Clean PET Flakes]
    G --> H[PET Recycling Stream]
    I[All Process Data] --> J[Distributed Ledger]
    B, C, F, G -- Generate --> I
    style A fill:#e6ffed,stroke:#333,stroke-width:2px
    style B fill:#cceeff,stroke:#333,stroke-width:2px
    style C fill:#fffacd,stroke:#333,stroke-width:2px
    style D fill:#ffddcc,stroke:#333,stroke-width:2px
    style E fill:#add8e6,stroke:#333,stroke-width:2px
    style F fill:#d8bfd8,stroke:#333,stroke-width:2px
    style G fill:#ccffcc,stroke:#333,stroke-width:2px
    style H fill:#f0e68c,stroke:#333,stroke-width:2px
    style I fill:#90ee90,stroke:#333,stroke-width:2px
    style J fill:#a9d18e,stroke:#333,stroke-width:2px

4.5. The "Inverse" or Failure Mode

Derivative 4.5.1: Controlled Contamination Recycling for Non-Critical Secondary Feedstocks

  • Enabling Description: A method of recycling an article is designed for situations where perfect separation and clear resin recovery are not economically feasible or technically required, resulting in a slightly contaminated, yet valuable, secondary feedstock. When an article (e.g., PET container with a metallic light-blocking label) is detected in a recycling stream but its full separation cannot be achieved (e.g., due to insufficient wash efficacy or high volume processing constraints), it is directed to a "controlled contamination" stream. Here, the article is chopped and washed in a less aggressive, lower-energy process (e.g., ambient temperature water wash with minimal agitation), intentionally leaving a small percentage of residual ink and light blocking particles (e.g., <2% by weight) on the plastic flakes. The resulting slightly off-color or speckled flakes are then processed into a secondary PET feedstock suitable for non-critical applications (e.g., garden furniture, construction materials, fiberfill) where slight pigmentation from the light blocking components is acceptable. This "failure" to achieve perfect clarity is a designed trade-off for higher throughput and reduced processing costs, expanding the economic viability of recycling.
flowchart TD
    Start --> ArticleInRecycling[Article in Recycling Stream]
    ArticleInRecycling --> AssessSeparability{Full Separation Achievable?}
    AssessSeparability -- No / Cost Prohibitive --> ControlledContaminationMode
    AssessSeparability -- Yes --> HighPurityRecyclingMode
    HighPurityRecyclingMode --> ChopWashFull[Chop & Wash (High Efficacy)]
    ChopWashFull --> CleanResin[Clean, Clear Recycled Resin]
    ControlledContaminationMode --> ChopWashPartial[Chop & Wash (Lower Efficacy/Energy)]
    ChopWashPartial --> ContaminatedResin[Slightly Contaminated Recycled Resin]
    CleanResin --> HighValueProducts[High-Value Products (e.g., food packaging)]
    ContaminatedResin --> LowValueProducts[Lower-Value Products (e.g., industrial goods)]
    HighValueProducts --> End
    LowValueProducts --> End
    style ControlledContaminationMode fill:#ffc,stroke:#333,stroke-width:2px
    style HighPurityRecyclingMode fill:#afa,stroke:#333,stroke-width:2px
    style CleanResin fill:#add8e6,stroke:#333,stroke-width:2px
    style ContaminatedResin fill:#faa,stroke:#333,stroke-width:2px

Combination Prior Art Scenarios

These scenarios combine aspects of US Patent 11961422 with existing open-source standards, demonstrating how the patented concepts can be rendered obvious or non-novel in combination with publicly available knowledge.

  1. US11961422 (Recyclable Shrink Label) + GS1 Digital Link Standard:

    • Description: An article, as described in US11961422 (e.g., a PET bottle with a light-blocking PET shrink label), incorporates an indicia layer that includes a GS1 Digital Link URI encoded in a Data Matrix or QR code. The GS1 Digital Link standard provides a globally unique identifier for products and can resolve to various types of information (e.g., recycling instructions, product provenance, sustainability data) via web links. The method of making this label (Claim 22) would involve printing the Digital Link URI alongside traditional graphics. The method of recycling (Claim 23) would still involve standard PET recycling, but the presence of the Digital Link allows for enhanced consumer engagement regarding recycling information and material traceability, which is a common public initiative. The interoperability of a recyclable label with a standard for digital product information, especially when linking to recycling protocols, makes the concept of a "smart" recyclable label obvious.
    • Prior Art Obviousness: The application of a standardized, openly available digital identifier (GS1 Digital Link) to a recyclable label for containers, where the label itself facilitates the container's recyclability, would be obvious to a person skilled in the art of packaging and supply chain management. The combination leverages the label's existing information-carrying capacity with a standard for dynamic information delivery.

  2. US11961422 (Light Blocking Layer) + Open-Source CAD/CAM for Gravure Cylinder Engraving:

    • Description: The method of making a label (Claim 22) specifies depositing a light blocking composition using gravure printing, with parameters like cell volume, cell width, channel width, and line screen. Open-source CAD/CAM software (e.g., FreeCAD, OpenSCAD, and various open-source CAM tools) allows for the precise design and generation of engraving paths for gravure cylinders. A skilled engineer, using such open-source tools, could model various cell geometries and channel configurations, and simulate their ink transfer characteristics, to optimize the application of a light blocking component to achieve a specific opacity (e.g., blocking 80% of light from 200-900 nm). The knowledge of how to manipulate engraving parameters to control ink laydown, combined with the publicly known properties of various light-blocking pigments, makes the development of a specific light-blocking layer design an obvious engineering exercise.
    • Prior Art Obviousness: The use of readily available open-source CAD/CAM tools to design and optimize gravure cylinder engravings for the purpose of controlling ink or coating deposition, including a light-blocking composition, is an obvious engineering practice in the printing and packaging industry. The application of such tools to achieve a desired optical property (light blocking) on a shrink film is a direct extension of known design and manufacturing principles.

  3. US11961422 (PET-compatible Recycling) + Open-Source PET Flake Sorting Algorithms (e.g., for OpenCV/Python):

    • Description: The method of recycling an article (Claim 23) emphasizes identifying PET containers and labels and directing them into a PET recycling stream, with washing to remove inks and pigments. In modern recycling facilities, advanced optical sorting systems are often employed. Open-source computer vision libraries like OpenCV, combined with Python programming, provide tools and algorithms for image processing, object detection, and classification. A skilled developer could implement algorithms (e.g., based on color, texture, shape analysis, or even subtle spectral differences) using publicly available hardware platforms (e.g., Raspberry Pi with a camera and spectral sensor) to identify PET flakes and differentiate between flakes with residual pigments/inks versus clean PET, and further, to distinguish PET from other plastics. While US11961422 focuses on the chemical wash, the upstream sorting of mixed plastic streams is a crucial part of the process. The combination highlights the obvious integration of open-source sorting technologies to enhance or precede the specific washing steps.
    • Prior Art Obviousness: The application of open-source computer vision algorithms and hardware (like those available through OpenCV) for the automated sorting and identification of plastic flakes, including PET, in a recycling stream is a known and continuously developing field. Integrating such a sorting system to identify articles that comprise PET (container and label) before directing them to a PET-specific wash stream is an obvious application of existing technology to optimize recycling efficiency as described in the patent.

Generated 5/18/2026, 12:46:57 PM