Epoxy UV Curable Composition for High Thermal Deflection
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Solution Overview
Problem
Current UV curable photopolymers are inadequate for real manufacturing applications requiring high thermal deflection temperature (HDT) and mechanical performance, as they are primarily suited for prototyping and do not meet the demands of industrial applications such as the automotive industry for components like interior parts and connectors.
Innovation Solution
A 1K epoxy dual cure composition is developed, comprising a light polymerizable liquid, an epoxy precursor, and a photoinitiator, which exhibits excellent storage stability and viscosity control, allowing for the formation of objects with high HDT and toughness through a process involving UV curing and subsequent thermal treatment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If traditional acrylate-based photopolymers are used for 3D printing, then prototyping can be achieved, but thermal deflection temperature and mechanical performance are insufficient for real manufacturing applications
Solution Approach 1:
The patent uses a composite system combining epoxy precursor (for high thermal and mechanical properties) with light polymerizable liquid (for UV curability). This composite approach allows the material to achieve both prototyping speed and manufacturing-grade performance, resolving the contradiction between temperature resistance and mechanical reliability.
Solution Approach 2:
The patent changes the chemical composition parameters by using epoxy precursor instead of traditional acrylate-based polymers. This parameter change fundamentally alters the material properties, enabling high thermal deflection temperature while maintaining curability through UV exposure, thus resolving the performance insufficiency for real manufacturing.
2Temperature
If epoxy precursors are mixed with curing agents to achieve high performance, then thermal and mechanical properties improve, but viscosity increases rapidly making storage and processing difficult
Solution Approach 1:
The patent segments the curing system into two separate components: epoxy precursor (stored separately) and light polymerizable liquid with photoinitiator. This segmentation prevents premature reaction, maintaining low viscosity and storage stability, while allowing high-performance curing when combined through UV exposure, thus resolving the contradiction between thermal performance and storage stability.
Solution Approach 2:
The light polymerizable liquid acts as an intermediary that enables controlled reaction. It contains the photoinitiator that triggers curing only when exposed to UV light, preventing spontaneous reaction between epoxy precursor and curing agents during storage. This intermediary mechanism resolves the contradiction by decoupling mixing from curing activation.
3Temperature
If epoxy precursors react rapidly upon mixing to achieve high performance, then thermal properties improve, but the material cannot be used as 1K resin requiring no pre-mixing process
Solution Approach 1:
The patent merges the curing agent functionality into the light polymerizable liquid component, which already contains photoinitiator. This merging creates a single-component (1K) system where epoxy precursor is combined with light polymerizable liquid and photoinitiator in one formulation, eliminating the need for separate mixing operations while maintaining high thermal performance through UV-triggered curing.
Solution Approach 2:
The patent replaces the mechanical mixing activation method with optical activation. Instead of requiring mechanical mixing to initiate reaction, the system uses UV light exposure to trigger curing. This substitution maintains high thermal performance while dramatically improving ease of use, as no pre-mixing process is required— simply apply and expose to UV light.
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 enables the creation of objects with improved thermal and mechanical properties, meeting the requirements of industrial applications by maintaining low viscosity over time and ensuring high printing accuracy.
Implementation Method 1
Photopolymers are a class of polymeric materials that changes their properties when exposed to light, often in the ultraviolet or visible region of the electromagnetic spectrum. These changes are often manifested structurally, such as liquid resin hardening into solid as a result of cross-linking when exposed to light.
Implementation Method 2
A 1K epoxy dual cure composition is developed, comprising a light polymerizable liquid, an epoxy precursor, and a photoinitiator, which exhibits excellent storage stability and viscosity control, allowing for the formation of objects with high HDT and toughness through a process involving UV curing and subsequent thermal treatment.
Data Source
AI summary
This disclosure relates to a curable composition comprising (a) at least one light polymerizable liquid; (b) at least one epoxy precursor dissolved in component (a); and (c) at least one photoinitiator; wherein the curable composition exhibits no more than 15% increase in viscosity at 25° C. after 7 days at room temperature.