Curable Compositions Using Reactive Comonomers for Fast Curing
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Solution Overview
Problem
Radiation-curable compositions based on methacrylate-functionalized compounds often compromise physical properties when increasing the proportion of acrylate-functionalized compounds to achieve faster curing, and acrylate-functionalized compounds pose health hazards and have poor cure speed with conventional radiation sources, especially with long wavelength LED systems.
Innovation Solution
Incorporating reactive monomers with a carbon atom di-substituted by carbonyl-containing groups, such as methylene malonates, into compositions with methacrylate-functionalized compounds to enhance curing kinetics and physical properties, allowing for faster curing with lower UV exposure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If the proportion of acrylate-functionalized compounds is increased to achieve faster curing, then the cure rate is improved, but the physical properties of the cured product deteriorate
Solution Approach 1:
The patent changes the chemical structure parameter of the comonomer from conventional acrylate to a novel compound with carbonyl-containing substituents (ketone, ester, or amide groups) on the alkene carbon. This structural parameter change enables faster curing kinetics while maintaining physical properties, resolving the contradiction between cure rate and physical property quality.
Solution Approach 2:
The patent creates a composite formulation combining methacrylate-functionalized compounds with the novel reactive comonomers featuring carbonyl-substituted alkenes. This composite approach leverages the high strength contribution of methacrylates while the novel comonomer provides accelerated curing, achieving both fast cure and excellent physical properties simultaneously.
2Productivity
If acrylate-functionalized compounds are used to promote faster reaction rate, then the cure speed is improved, but health hazards and irritation increase
Solution Approach 1:
The patent modifies the chemical composition parameter by replacing acrylate-functionalized compounds with novel reactive comonomers containing carbonyl-substituted alkene groups. This compositional change maintains fast cure speed while reducing health hazards and irritation, as the new comonomer structure is less irritating than conventional acrylates.
3Reliability
If conventional radiation sources are used with acrylate-functionalized compounds, then curing can proceed, but the cure speed is poor especially with long wavelength LED systems
Solution Approach 1:
The patent changes the absorption characteristics parameter of the reactive monomers by introducing carbonyl-containing groups (ketone, ester, or amide) that enhance absorption of long wavelength radiation. This enables effective curing with long wavelength LED systems while maintaining fast cure speed, overcoming the limitation of conventional radiation sources.
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 use of reactive comonomers like methylene malonates in curable compositions results in faster curing and improved physical properties, achieving a synergistic effect that maintains high performance while reducing the need for higher acrylate-functionalized compound content, thus addressing health hazards and cure speed limitations.
Implementation Method 1
curable compositions based on admixtures of (meth)acrylate-functionalized compounds and reactive comonomers which are capable of being cured by exposure to radiation (e.g., ultraviolet radiation)
Data Source
AI summary
Curable compositions having desirable attributes such as rapid curing rates and enhanced physical properties are prepared using admixtures of one or more (meth)acrylate-functionalized compounds and one or more reactive comonomers, such as 1,1-diester-1-alkenes (e.g., methylene malonates), 1,1-diketo-1-alkenes, 1-ester-1-keto-1-alkenes and/or icatonates.