Curable Sheet Composition Adhesion to Glass Substrate
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Solution Overview
Problem
Conventional methods for molding optical parts on glass substrates face issues such as poor adhesion, bubble inclusion, and the need for pre-treatment with coupling agents, leading to durability and weathering resistance problems.
Innovation Solution
A curable sheet composition comprising 50-94% urethane (meth)acrylate oligomer, 5-40% (meth)acrylate with a carboxyl group, and 0.3-10% photopolymerization initiator, which is in a solid state at room temperature but liquefies and cures upon heating and actinic energy exposure, allowing direct molding on glass substrates without pre-treatment and ensuring high adhesion and transparency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a curable sheet composition is used for direct molding on glass substrate, then handling ease and film thickness control are improved, but adhesion to glass substrate deteriorates causing peeling
Solution Approach 1:
The patent changes the chemical composition parameters of the curable sheet by incorporating specific adhesive promoters (silane coupling agents, titanate coupling agents, or aluminate coupling agents) at controlled concentrations (0.1-5 wt%, 0.1-3 wt%, or 0.01-1 wt% respectively) to enhance adhesion to glass substrate while maintaining the sheet's handling properties
Solution Approach 2:
The patent creates a composite curable sheet material by combining the base curable composition with adhesive promoter additives, forming a multi-component system that simultaneously provides both ease of handling and strong adhesion to glass substrate
2Reliability
If coupling agent treatment is applied to glass substrate, then adhesion between curable composition and glass is improved, but number of manufacturing steps increases
Solution Approach 1:
The patent merges the adhesion promotion function into the curable sheet composition itself by incorporating adhesive promoters directly into the material, eliminating the need for separate coupling agent treatment of the glass substrate and reducing manufacturing steps
Solution Approach 2:
The curable sheet composition becomes self-sufficient for adhesion promotion by containing built-in adhesive promoters, eliminating the need for external pre-treatment of the glass substrate with coupling agents
3Reliability
If pasty curable composition is used, then adhesion can be enhanced with coupling agents, but bubble mixing and protrusion problems occur
Solution Approach 1:
The patent changes the physical state parameter of the curable material from paste to solid sheet form, which eliminates bubble inclusion and protrusion issues while maintaining adhesion through incorporated adhesive promoters
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 solution provides a handleable, bubble-free, and transparent cured product with superior adhesion and weathering resistance, enabling long-term outdoor use of optical elements.
Implementation Method 1
radiating actinic energy beam to the softened or melted composition to cure the composition
Implementation Method 2
heating to a temperature of 40° to 100° C., thereby allowing the composition to soften or melt
Data Source
AI summary
A curable sheet composition able to follow up a mold shape under the application of heat and pressure, able to polymerize and cure upon being irradiated with light, permitting an optical element molding pattern to be fixed, and comprising 50% to 94% of a polycarbonate diol-modified urethane acrylate oligomer, 5% to 40% of a (meth)acrylate containing at least one carboxyl group in each molecule thereof, and 0.5% to 5% of a photopolymerization initiator.