Curable Resin Composition for Heat-Resistant Optical Components
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods for producing plastic optical components with heat resistance for reflow processes are inadequate, as they either deform under heat or suffer from burr formation during molding, leading to low product quality and high production costs.
Innovation Solution
A method involving a curable resin composition with a non-conjugated vinylidene group-containing compound, processed through photoirradiation and thermal polymerization to achieve a specific viscosity range, allowing for controlled formability and heat resistance, preventing burr formation and improving the molding process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If thermoplastic resin is used for optical elements, then workability is improved, but heat resistance deteriorates
Solution Approach 1:
The patent changes the chemical composition parameters of the resin by incorporating specific compounds (polyfunctional monomers with 20-80 mass% content, multifunctional crosslinking agents with 5-50 mass% content) to transform the material from thermoplastic to thermosetting characteristics, achieving both good workability and heat resistance
Solution Approach 2:
The patent creates a composite resin system combining multiple components: polyfunctional monomers, multifunctional crosslinking agents, photopolymerization initiators, and optional inorganic fillers. This composite approach achieves synergistic effects where the combination provides both the flowability needed for molding and the heat resistance for reflow processes
2Temperature
If photocurable resin is used for optical elements, then heat resistance is improved, but burr formation increases
Solution Approach 1:
The patent adjusts the viscosity parameter of the photocurable resin by controlling the molecular weight and functional group content of the polyfunctional monomers and crosslinking agents, achieving an optimal balance between flowability (to prevent burr formation) and heat resistance (through crosslinking density)
Solution Approach 2:
The patent creates different local properties within the resin system: the polyfunctional monomers provide low viscosity and good flowability for mold filling, while the multifunctional crosslinking agents provide high crosslinking density and heat resistance in the cured state, with each component performing its specific function locally
3Ease of operation
If viscosity of photocurable resin is reduced for good workability, then moldability is improved, but leakage through parting line increases
Solution Approach 1:
The patent optimizes the viscosity parameter by selecting polyfunctional monomers and crosslinking agents with appropriate molecular weights and functional group densities, achieving a viscosity range that ensures complete mold filling without excessive leakage through the parting line
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 method produces high-quality, heat-resistant plastic optical components with reduced burr formation and increased product transferability, enhancing the efficiency and cost-effectiveness of the reflow process.
Implementation Method 1
a curable resin composition containing a (meth)acrylate monomer, a non-conjugated vinylidene group-containing compound and a thermal radical-polymerization initiator is processed by at least one of photoirradiation and heating
Implementation Method 2
a thermal polymerization step of putting the semi-cured product in a forming die for pressure formation therein, and heating it therein for thermal polymerization to give a cured product
Data Source
AI summary
A heat-resistant cured product is efficiently produced by obtaining a semi-cured product where a curable resin composition containing a (meth)acrylate monomer, a non-conjugated vinylidene group-containing compound and a thermal radical-polymerization initiator is processed by at least one of photoirradiation and heating to give a semi-cured product having a complex viscosity of from 105 to 108 mPa·s at 25° C. and at a frequency of 10 Hz; and putting the semi-cured product in a forming die for pressure formation therein, and heating it therein for thermal polymerization to give a cured product.