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<p>Multilayer plastic packaging offers essential barrier and mechanical properties for food preservation, but its complex structure prevents effective recycling. Here, we report a light-responsive thermoplastic adhesive designed to enable on-demand separation of polymer layers in multilayer packaging. The adhesive adopts a triblock architecture with terminal blocks compatible with polyethylene (PE) and polyamide (PA), and a central segment functionalised with coumarin-based photoremovable groups. Upon ultraviolet (UV) exposure, the adhesive undergoes complete molecular breakdown, triggering clean delamination without solvents or mechanical force. Fabricated PE – photosensitive adhesive – PA films demonstrated superior adhesion performance compared to a commercial benchmark during service life, and efficient separation upon irradiation, as confirmed by Fourier transform infrared (FTIR) spectroscopy, microscopy, and T-peel testing. Life cycle assessment revealed that, while the laboratory-scale synthesis has higher environmental costs, the impact is offset after a single reuse cycle in projected industrial conditions, reaching up to 80% reduction after six cycles. This approach provides a scalable strategy to reconcile performance and recyclability in multilayer packaging.</p><p></p>

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Coumarin-inspired light-responsive thermoplastic adhesives for recyclable multilayer packaging

  • 期刊论文

  • 出版模式：

    开放获取

  • 发表日期：

    2025年12月24日

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  • Carlos Sedano,
  • Manuel Herrero,
  • Miriam Trigo-López,
  • Miguel Angel Rodríguez-Pérez,
  • Juan Carlos Merino,
  • José Miguel García,
  • Saul Vallejos,
  • Karina C. Núñez Carrero

摘要

Multilayer plastic packaging offers essential barrier and mechanical properties for food preservation, but its complex structure prevents effective recycling. Here, we report a light-responsive thermoplastic adhesive designed to enable on-demand separation of polymer layers in multilayer packaging. The adhesive adopts a triblock architecture with terminal blocks compatible with polyethylene (PE) and polyamide (PA), and a central segment functionalised with coumarin-based photoremovable groups. Upon ultraviolet (UV) exposure, the adhesive undergoes complete molecular breakdown, triggering clean delamination without solvents or mechanical force. Fabricated PE – photosensitive adhesive – PA films demonstrated superior adhesion performance compared to a commercial benchmark during service life, and efficient separation upon irradiation, as confirmed by Fourier transform infrared (FTIR) spectroscopy, microscopy, and T-peel testing. Life cycle assessment revealed that, while the laboratory-scale synthesis has higher environmental costs, the impact is offset after a single reuse cycle in projected industrial conditions, reaching up to 80% reduction after six cycles. This approach provides a scalable strategy to reconcile performance and recyclability in multilayer packaging.