Hybrid Photocurable Composition for Fast LED Curing
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Solution Overview
Problem
Existing light-curable hybrid systems used in additive manufacturing, particularly those containing acrylate, epoxy, and oxetane resins, face challenges with slow cure speeds when exposed to longer wavelengths and lower intensity light, such as those provided by LED and LCD curing systems.
Innovation Solution
The development of an actinic radiation curable composition comprising a high proportion of oxetane functional compounds, up to 80% by weight based on the total weight of oxetane and epoxy functional compounds, along with epoxy and acrylate functional compounds, and at least one photoinitiator, which enhances cure speed and achieves mechanical properties comparable to conventional systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If LED or LCD curing systems with longer wavelengths and lower intensity are used, then environmental friendliness and cost are improved, but cure speed deteriorates
Solution Approach 1:
The invention changes the chemical composition parameters of the resin system by incorporating cationically curable compounds (epoxies and oxetanes) with specific functional groups that have extended absorption spectra. This allows the resin to absorb longer wavelength UV light more effectively, maintaining cure speed while using LED/LCD curing systems with wavelengths of 365-405 nm.
Solution Approach 2:
The invention creates a hybrid resin composition that combines acrylate-based photopolymerizable compounds with cationically curable epoxy and oxetane compounds. This composite material system leverages both free-radical and cationic polymerization mechanisms, enabling the formulation to cure effectively under LED/LCD wavelengths while maintaining high productivity.
2Stability of the object's composition
If oxetane-based resins are used to reduce shrinkage, then shrinkage is reduced, but cure speed deteriorates
Solution Approach 1:
The invention merges oxetane-based cationic curable compounds with acrylate-based photopolymerizable compounds in a hybrid resin system. The acrylate component provides rapid free-radical polymerization that compensates for the slower cationic cure of oxetanes, while the oxetane component maintains low shrinkage. The synergistic combination achieves both fast cure speed and reduced shrinkage simultaneously.
3Stability of the object's composition
If epoxy and oxetane materials are used to reduce shrinkage, then shrinkage is reduced, but green strength deteriorates
Solution Approach 1:
The invention optimizes the weight ratio parameters of the hybrid resin composition, specifically formulating with 5-50 wt% acrylate-based photopolymerizable compounds and 50-95 wt% cationically curable compounds (epoxies and oxetanes). This parameter optimization ensures that sufficient acrylate content provides rapid initial cure and green strength, while the dominant cationic component maintains low shrinkage.
4Strength
If higher proportion of oxetane is used to improve green strength, then green strength is improved, but cure speed deteriorates under LED/LCD systems
Solution Approach 1:
The invention changes the photoinitiator system parameters by selecting cationic photoinitiators with absorption maxima in the 365-405 nm range that match LED and LCD curing systems. This allows high proportions of oxetane (55-90 wt% of cationic curable compounds) to be used while maintaining fast cure speed under LED/LCD wavelengths, as the photoinitiator efficiently absorbs the available light and initiates rapid cationic polymerization.
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 composition significantly improves the cure speed of hybrid systems, achieving faster printing performance, stronger green strength, improved mechanical properties, and better thermodynamic properties, even under the lower intensity light conditions of LED and LCD curing systems.
Implementation Method 1
actinic radiation curable composition comprising a high proportion of oxetane functional compounds, up to 80% by weight based on the total weight of oxetane and epoxy functional compounds, along with epoxy and acrylate functional compounds, and at least one photoinitiator
Data Source
AI summary
An actinic radiation curable composition includes one or more oxetane functional compounds; b) one or more epoxy functional compounds; c) one or more (meth) acry late functional compounds; and d) one or more photoinitiators. The oxetane functional compounds are present in the composition at from 55% to 90%, preferably from 60% to 90%, more preferably from 70% to 90%, by weight based on the total weight of the oxetane functional compounds and the epoxy functional compounds in the composition.