Dual-Cure Resin Composition for UV Shadow and Shear Adhesion
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Solution Overview
Problem
Conventional UV- and thermo-curable adhesives face issues with peeling and misalignment of parts during transportation due to stress, especially shear stress, and inadequate adhesive strength in areas not fully UV-irradiated, leading to insufficient peel and shear strength in final assemblies.
Innovation Solution
A curable resin composition comprising polyfunctional (meth)acrylate, monofunctional (meth)acrylate, epoxy resin, polyfunctional thiol compound, photo-radical initiator, and thermal curing accelerator, with specific ratios of functional groups to achieve high adhesive strength after UV and thermal curing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a polyfunctional monomer having both carboxyl group and hydroxyl group is used in a specific amount, then the crosslinking reaction is promoted and storage stability is improved, but the resin composition becomes unsuitable for dental use when the amount exceeds the specification
Solution Approach 1:
The patent precisely controls the amount of polyfunctional monomer within a specific range (0.1-10 wt% based on total resin composition) to optimize both storage stability and dental applicability. This parameter optimization resolves the contradiction by identifying the optimal concentration window where the monomer promotes crosslinking without causing excessive polymerization or adverse reactions.
Solution Approach 2:
The patent creates a composite resin system combining multiple components: monofunctional monomers, polyfunctional monomers with specific amounts of carboxyl and hydroxyl groups, photoinitiators, and fillers. This composite approach allows the system to achieve both storage stability through controlled crosslinking and suitability for dental applications through balanced formulation.
2Ease of manufacture
If conventional resin compositions are used, then the material is available for restorative materials, but it causes tooth sensitivity and secondary caries due to polymerization shrinkage and lack of adhesion to tooth walls
Solution Approach 1:
The polyfunctional monomer acts as a intermediary that bridges the resin matrix and tooth structure. Its dual functionality (carboxyl and hydroxyl groups) enables it to interact with both the organic resin components and the inorganic tooth substrate, improving adhesion and reducing the harmful effects of polymerization shrinkage.
Solution Approach 2:
The patent modifies the chemical composition parameters of the resin by incorporating specific amounts of polyfunctional monomers with carboxyl and hydroxyl groups. This compositional change reduces polymerization shrinkage and improves bonding to tooth walls, thereby eliminating tooth sensitivity and secondary caries while maintaining restorative material availability.
3Stability of the object's composition
If the resin composition is designed for high crosslinking reaction, then storage stability is achieved, but the composition becomes unsuitable for dental applications
Solution Approach 1:
The patent identifies and controls multiple compositional parameters simultaneously: the type of monomers, the amount of polyfunctional monomer (0.1-10 wt%), the ratio of carboxyl to hydroxyl groups, and the presence of photoinitiators. By optimizing these parameters within specific ranges, the composition achieves both storage stability through crosslinking and suitability for dental applications.
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 provides enhanced peel and shear strength in UV- and thermo-cured products, ensuring strong adhesion and preventing misalignment in semiconductor devices and sensor modules.
Implementation Method 1
a curable resin composition comprising a polyfunctional monomer having both a carboxyl group and a hydroxyl group, and a photoinitiator
Data Source
AI summary
The object of the present invention is to provide a UV- and thermo-curable resin composition that exhibits sufficiently high adhesive strength when subjected to only either UV-curing treatment or heat-curing treatment. The present invention provides a curable resin composition comprising the following components (A) to (F): (A) a polyfunctional (meth)acrylate compound, (B) a monofunctional (meth)acrylate compound with a molecular weight of 400 or less, (C) an epoxy resin, (D) a polyfunctional thiol compound, (E) a photo-radical initiator, and (F) a thermal curing accelerator, wherein total number (total amount) of (meth)acryloyl groups for the (A) polyfunctional (meth)acrylate compound, total number (total amount) of (meth)acryloyl groups for the (B) monofunctional (meth)acrylate compound, total number (total amount) of epoxy groups for the (C) epoxy resin, and total number (total amount) of thiol groups for the (D) polyfunctional thiol compound satisfy a predetermined relationship.