Transesterification Curable Composition for Low Viscosity Hard Films
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Solution Overview
Problem
Current active energy beam-curable compositions, particularly those using dipentaerythritol pentaacrylate and pentaerythritol tetraacrylate, face issues with high viscosity, low film hardness, emulsification stability, and residual metal ions, which affect the performance of coatings, inks, and pattern formation agents.
Innovation Solution
A curable composition is developed using a transesterification reaction of diglycerin and/or glycerin with a monofunctional (meth)acrylate, employing a combination of specific basic and zinc-based catalysts to reduce viscosity, enhance curing speed, and improve film hardness and alkali developability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If DPHA and PETTA are used as main components for hard coating, then surface hardness and scratch resistance are improved, but viscosity becomes excessively high making solventless formation difficult
Solution Approach 1:
The patent changes the chemical parameters of the polyol component by using specifically synthesized polyols with controlled molecular weights and hydroxyl values. This allows achieving low viscosity while maintaining the crosslinking density needed for hard curing films.
Solution Approach 2:
The patent creates a composite curable composition combining the synthesized polyol with specific (meth)acrylates and photopolymerization initiators. This composite approach balances viscosity reduction with maintained curing performance and film hardness.
2Ease of manufacture
If DPHA and PETTA are produced via dehydration esterification, then production is achieved, but high-molecular-weight bodies remain causing reduction of cured film hardness
Solution Approach 1:
The patent extracts and removes high-molecular-weight bodies from the polyol product through filtration and other purification steps. This eliminates the harmful side products that would otherwise reduce cured film hardness while maintaining the production route.
Solution Approach 2:
The patent changes the production parameters by controlling reaction conditions, molecular weight, and hydroxyl value during polyol synthesis. This prevents excessive polymerization and minimizes high-molecular-weight body formation in the first place.
3Reliability
If DPHA is used for offset ink due to excellent surface curing ability, then curing performance is improved, but emulsification stability is reduced due to high-molecular-weight bodies
Solution Approach 1:
The patent removes high-molecular-weight bodies through filtration and purification processes. This eliminates the cause of emulsification instability while preserving the curable components that provide surface curing ability.
Solution Approach 2:
The patent optimizes the molecular weight and hydroxyl value parameters of the polyol to achieve a balance between curability and emulsion stability, preventing excessive chain growth that would compromise stability.
4Ease of manufacture
If alkali metal aqueous solution is used for removing unreacted acrylic acid, then purification is achieved, but metal ions remain at 1 ppm or more causing reduction of electric properties
Solution Approach 1:
The patent replaces the conventional alkali metal aqueous solution with a non-aqueous base solution that does not leave harmful metal ions. This substitution eliminates the source of ion elution while maintaining purification effectiveness.
Solution Approach 2:
The patent changes the chemical composition parameter of the washing solution from aqueous to non-aqueous base solution, fundamentally altering the purification mechanism to avoid metal ion contamination.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The composition achieves low viscosity, rapid curing, high film hardness, and excellent emulsification stability, while minimizing residual metal ions, thus addressing the limitations of existing compositions.
Implementation Method 1
the composition includes a photopolymerization initiator and curable upon irradiation with an active energy beam
Implementation Method 2
A curable composition is developed using a transesterification reaction of diglycerin and/or glycerin with a monofunctional (meth)acrylate, employing a combination of specific basic and zinc-based catalysts
Data Source
AI summary
Provided is a method for making a curable composition that has low viscosity and rapid curing ability in the form of thin film, further has excellent resistance to emulsification and preservation stability, and has high hardness in the form of cured film, thereby achieving excellent alkali developability, which is preferably an active energy beam-curable composition, is provided. The made curable composition includes a mixture (A) of a compound having two or more (meth)acryloyl groups, and is obtained by conducting a transesterification reaction of diglycerin and/or glycerin and a compound having one (meth)acryloyl group under the presence of the following catalysts X and Y: catalyst X: a compound that is at least one member selected from the group consisting of cyclic tertiary amine having an azabicyclo structure or a salt or complex thereof, amidine or a salt or complex thereof, and a compound having a pyridine ring or a salt or complex thereof; and catalyst Y: a compound including zinc.