Curable Resin Composition for Optical Modules
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Solution Overview
Problem
Conventional light-shielding materials, such as carbon black, increase viscosity and reduce coating workability in resin compositions, and can cause epoxy resin crystallization, while surfactants used to improve workability may adversely affect durability.
Innovation Solution
A curable resin composition incorporating a composite of epoxy resin and a carbon material with a graphene layered structure, such as partially exfoliated graphite, which enhances light-shielding properties across a wide wavelength range without increasing viscosity and promotes storage stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If inorganic filler such as carbon black is used as light-shielding material, then light-shielding properties are improved, but viscosity increases and coating workability deteriorates
Solution Approach 1:
The patent uses a polymerizable compound as an intermediary substance that bridges the inorganic filler (carbon black) and the resin matrix. This compound adsorbs onto the filler surface through its polymerizable group and integrates into the polymer network through polymerization, thereby improving filler dispersion and reducing viscosity increase while maintaining light-shielding properties
Solution Approach 2:
The patent creates a composite material system consisting of resin, inorganic filler (carbon black), and polymerizable compound. This composite approach allows the polymerizable compound to modify the interface between filler and resin, improving overall composition homogeneity and coating workability while preserving the light-shielding function of carbon black
2Object-affected harmful factors
If inorganic filler such as carbon black is blended in epoxy resin, then light-shielding properties are improved, but epoxy resin crystallizes easily requiring heating before coating
Solution Approach 1:
The polymerizable compound acts as an intermediary that prevents direct interaction between epoxy resin molecules and inorganic filler surfaces that would otherwise promote crystallization. By adsorbing onto filler surfaces and participating in polymerization, it creates a steric barrier that disrupts crystal lattice formation, thereby preventing crystallization without requiring heating
Solution Approach 2:
The patent changes the molecular structure and interaction parameters of the system by introducing polymerizable compounds with specific functional groups. This modifies the physical and chemical parameters of the epoxy resin-filler system, suppressing crystallization tendency and improving storage stability at room temperature
3Ease of operation
If surfactants are used to enhance affinity between inorganic filler and liquid component, then viscosity and coating workability are improved, but surfactants remain in final cured product and adversely affect durability
Solution Approach 1:
The patent extracts and eliminates harmful surfactants from the final cured product by replacing them with polymerizable compounds that become part of the polymer network. This substitution removes the source of durability degradation while maintaining the desired coating workability and filler affinity
Solution Approach 2:
The polymerizable compound serves as a temporary processing aid during application that is then consumed and integrated into the permanent polymer structure during curing. This replaces the problematic approach of using persistent surfactants with a consumable intermediate that leaves no harmful residues
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 excellent coating workability and light-shielding properties from visible light to near-infrared regions, preventing unnecessary light interference and improving image quality in optical modules, while maintaining low viscosity and preventing epoxy resin crystallization.
Implementation Method 1
the curable resin composition having light-shielding properties... excellent light-shielding properties in the visible light region to the near-infrared region
Data Source
AI summary
Provided is a curable resin composition capable of forming a member having excellent coating workability and excellent light-shielding properties in the visible light region to the near-infrared region. The curable resin composition having light-shielding properties includes an epoxy resin and a composite containing a carbon material having a graphene layered structure and a resin, the curable resin composition having a content of the composite of 0.1 wt % or more and 30 wt % or less with respect to the entire curable resin composition.