Two-Component Epoxy Mass With UV-Triggered Uniform Curing
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Solution Overview
Problem
Existing two-component epoxy compositions suffer from limited formulation freedom, uncontrolled reaction rates leading to inhomogeneous properties between irradiated and unirradiated zones, and require complex shading processes, making them unsuitable for applications requiring uniform mechanical properties and extended processing times.
Innovation Solution
A curable, two- or multi-component composition comprising a difunctional nitrogen-based hardener, a radiation-curable hybrid compound with both methacrylate and epoxide groups, and a photoinitiator, allowing for uniform mechanical properties and extended processing times, with optional heat curing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of moving object
If accelerators based on alcohols, metal salts, and/or tertiary amines are used to accelerate strength development, then the time until complete curing is improved, but the working time is reduced
Solution Approach 1:
The curing process is segmented into two distinct stages: an initial rapid curing stage enabled by photopolymerization of acrylate groups upon irradiation, providing immediate strength development during working time; and a final completion stage through polyaddition of epoxy groups and amines, which continues to develop full strength properties. This segmentation allows both adequate working time and accelerated curing to coexist.
Solution Approach 2:
The patent replaces thermal acceleration mechanisms (heat curing) with photopolymerization initiated by UV irradiation. This substitution enables rapid curing at room temperature without requiring elevated temperatures that would extend working time, thus resolving the contradiction between curing speed and operational flexibility.
2Adaptability or versatility
If primary amines are used as hardeners to reduce reaction reactivity with acrylate groups, then formulation freedom is improved, but uncontrollable consumption of amines occurs after mixing
Solution Approach 1:
The patent introduces photopolymerization of acrylate groups as an intermediary reaction pathway that occurs first upon irradiation. This intermediary process consumes the acrylate groups before the amine hardener can react with them, preventing uncontrolled amine consumption. The photopolymerization step acts as a protective intermediary that preserves amine availability for the subsequent epoxy-amine polyaddition reaction.
Solution Approach 2:
The patent performs preliminary action by irradiating the mixture to trigger photopolymerization of acrylate groups before the amine hardener can react with them. This preliminary photopolymerization step secures the acrylate groups in advance, preventing their premature reaction with amines and ensuring reliable and controlled amine consumption throughout the curing process.
3Productivity
If irradiation is applied to achieve quick initial strength, then productivity is improved, but inhomogeneous properties occur between irradiated and unirradiated areas
Solution Approach 1:
The patent employs a hybrid compound that serves multiple functions simultaneously: it contains both acrylate groups for photopolymerization and epoxy groups for polyaddition with amines. This multi-functionality ensures that irradiation triggers a comprehensive curing response throughout the entire material, including both irradiated and unirradiated areas, thereby achieving uniform mechanical properties while maintaining high productivity.
Solution Approach 2:
The patent changes the chemical composition parameter by using a hybrid compound with dual reactive groups (acrylate and epoxy) instead of conventional single-function compounds. This parameter change enables the material to respond uniformly to irradiation across all regions, eliminating property inhomogeneity while preserving the productivity benefits of rapid initial curing.
4Manufacturing precision
If complex shading processes are used to achieve uniform properties, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The patent extracts and eliminates the need for complex shading processes by using a photoinitiator system that activates throughout the entire material volume uniformly. The photopolymerization reaction proceeds homogeneously from the source of irradiation, naturally achieving uniform mechanical properties without requiring additional shading components or complex process control mechanisms.
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 uniform mechanical properties between irradiated and unirradiated zones, supports broad application flexibility, and allows for extended processing times without significant property differences, suitable for bonding, potting, and coating substrates.
Implementation Method 1
a radiation-curable hybrid compound with both radiation-curable groups and polyadditionally crosslinkable epoxy groups, and a photoinitiator
Implementation Method 2
a hybrid compound having both radiation-curable groups and polyadditionally crosslinkable epoxy groups
Data Source
AI summary
The invention relates to a curable, two- or more-component mass, comprising (a) optionally an at least bifunctional epoxide-containing compound; (b) an at least bifunctional nitrogen-based curing agent, which is suitable for the epoxide curing; (c) a radiation-curing hybrid compound, which has both one ore more radiation-curing methacrylate groups and one or more epoxide groups; (d) a radical photoinitiator; (e) optionally an accelerator for the epoxide curing and (f) optionally further additives. The invention further relates to a method for gluing, potting, molding or coating substrates using the mass.