Energy Modulation Agent for Deep Curing of Radiation-Curable Media
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Solution Overview
Problem
Light-activated processing in adhesive and surface coating applications is limited by the penetration depth of light, requiring direct exposure and leading to uneven curing due to 'shaded' areas and the presence of sealed skins, which increases cure time and complexity.
Innovation Solution
Incorporating a single energy modulation agent that emits radiation upon interaction with initiation energy, such as x-rays, gamma rays, microwaves, or radio waves, to induce changes in the medium, including curing of radiation-curable media, by converting initiation energy into a form that can penetrate and activate photoinitiators within the medium.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If light-activated processing is used for curing adhesive and surface coating compositions, then productivity is improved and energy consumption is reduced, but the penetration depth of light is limited causing uneven curing in shaded areas and increasing device complexity
Solution Approach 1:
The patent introduces an energy modulation agent as an intermediary substance that converts initiation energy (x-rays, gamma rays, microwaves, or radio waves) into radiation at wavelengths effective for activating photoinitiators. This mediator enables deep penetration through the medium while still producing the required activation effect, resolving the contradiction between fast surface curing and uniform deep curing.
Solution Approach 2:
The patent changes the parameter of radiation wavelength by using energy modulation agents that convert high-energy initiation radiation into specific wavelength ranges (UV, visible, or infrared) suitable for photoinitiator activation. This parameter transformation allows the use of penetrating initiation energy while maintaining the chemical effectiveness required for uniform curing throughout the medium.
2Device complexity
If conventional light sources are used for curing, then the process is simple, but the light cannot penetrate deep into the medium requiring direct exposure and secondary cure mechanisms
Solution Approach 1:
The energy modulation agent serves as a mediator that enables high-energy radiation (x-rays, gamma rays, microwaves, or radio waves) to penetrate deeply into the medium and be converted locally into activation radiation. This eliminates the need for complex secondary curing mechanisms while achieving uniform deep penetration.
Solution Approach 2:
The patent substitutes conventional optical light sources with a field-based approach using x-rays, gamma rays, microwaves, or radio waves that can penetrate through the medium without mechanical contact or line-of-sight requirements, thereby simplifying the processing system while increasing penetration depth.
3Manufacturing precision
If multiple energy modulation agents are used to achieve uniform curing, then curing uniformity is improved, but device complexity and cost increase
Solution Approach 1:
The patent employs a single energy modulation agent that performs multiple functions: it absorbs initiation energy across a broad spectrum (x-rays, gamma rays, microwaves, or radio waves), converts it to appropriate wavelengths for photoinitiator activation, and enables uniform curing throughout the medium. This multi-functional approach eliminates the need for multiple specialized agents.
Solution Approach 2:
The energy modulation agent changes the radiation parameter from high-energy initiation radiation to activation-effective wavelengths, and a single agent can handle this transformation across the entire medium volume, achieving uniform curing without requiring multiple agents at different locations or concentrations.
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
This method allows for uniform curing of radiation-curable media without the need for direct light exposure, reducing cure time and eliminating the 'cocoon effect' by using initiation energies that can penetrate the medium, thereby enhancing productivity and reducing energy consumption.
Implementation Method 1
an energy modulation agent configured to emit radiation into the medium upon interaction with an initiation energy
Implementation Method 2
The applied initiation energy interacts with the energy modulation agent to directly or indirectly produce the change in the medium by the emitted radiation
Implementation Method 3
The initiation energy interacts with the energy modulation agent to directly or indirectly cure the uncured medium by polymerization of polymers in the medium
Data Source
Figure 1
Figure 2~3A
Figure 3B
AI summary
A method and a system for producing a change in a medium. The method places in a vicinity of the medium an energy modulation agent. The method applies an initiation energy to the medium. The initiation energy interacts with the energy modulation agent to directly or indirectly produce the change in the medium. The energy modulation agent has a normal predominant emission of radiation in a first wavelength range outside of a second wavelength range (WR2) known to produce the change, but under exposure to the applied initiation energy produces the change. The system includes an initiation energy source configured to apply an initiation energy to the medium to activate the energy modulation agent.