Catalyst-Free Electron Beam Curing for Siliconized Fibrous Webs
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Solution Overview
Problem
Current methods for preparing siliconized fibrous webs require solvent-based silicones, thermal curing, and the use of catalysts and initiators, which are costly and inefficient, and often necessitate multiple coating and drying steps.
Innovation Solution
The method involves saturating a fibrous web with a polysiloxane composition and electron beam curing to form a crosslinked polysiloxane network, eliminating the need for catalysts and initiators, and optionally coating with a second polysiloxane composition for further curing, using non-functional polysiloxanes like poly dimethylsiloxane with minimal solvent content.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If solvent-based silicones and thermal curing with catalysts/initiators are used, then the fibrous web can be siliconized, but the process becomes costly and inefficient with multiple coating and drying steps
Solution Approach 1:
The patent extracts and eliminates catalysts and initiators from the silicone composition, using electron beam curing instead to achieve crosslinking. This removes the need for multiple coating and drying steps associated with thermal curing, simplifying the process and improving manufacturing efficiency
Solution Approach 2:
The patent changes the curing method from thermal curing to electron beam curing. This parameter change allows the silicone composition to crosslink without catalysts/initiators and without requiring multiple coating and drying cycles, thereby improving both ease of manufacture and productivity
2Reliability
If multiple coating and drying steps are used, then the fibrous web achieves adequate siliconization, but the manufacturing process becomes complex and time-consuming
Solution Approach 1:
The patent merges the coating and curing operations into a single step by using electron beam curing. The electron beam activates the crosslinking reaction directly in the coating layer, eliminating the need for separate drying and curing steps, thus reducing process complexity while maintaining siliconization quality
Solution Approach 2:
The patent applies the silicone composition in a single coating step that is immediately followed by electron beam curing. This preliminary action of proper composition formulation enables the material to crosslink effectively in one pass, eliminating the need for multiple coating and drying cycles
3Temperature
If catalysts and initiators are used in the silicone composition, then thermal curing can proceed, but the cost increases and the process becomes less efficient
Solution Approach 1:
The patent replaces the chemical curing mechanism (thermal curing with catalysts/initiators) with a physical curing mechanism (electron beam curing). The electron beam provides the energy needed for crosslinking without requiring chemical catalysts or initiators, thereby eliminating their cost and reducing the quantity of substances needed
Solution Approach 2:
The patent changes the curing activation method from thermal activation requiring catalysts to electron beam activation. This parameter change eliminates the need for catalysts and initiators while achieving effective crosslinking, reducing both cost and material quantity
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
This approach reduces the need for solvents and catalysts, simplifies the curing process, and results in a siliconized web with improved thermal stability, chemical resistance, and water-proofing, while maintaining the unique properties of silicone materials.
Implementation Method 1
electron beam curing the first composition to crosslink the polysiloxane materials
Implementation Method 2
crosslink the polysiloxane materials to form a cured, saturated web
Data Source
Figure 1
AI summary
Siliconized fibrous webs are described. The siliconized webs include a fibrous web saturated with an electron beam cured silicone composition. Siliconized webs with electron beam cured silicone coating are also described. Methods of preparing both the coated and uncoated siliconized fibrous webs are also described.