Light-Curable Silicone Composite Molding via UV Curing

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Solution Overview

Problem

Existing methods for producing composite molded bodies using thermoplastics and elastomers are energetically unfavorable due to the need for multiple heating steps and limited use of low-melting, cost-effective plastics with low heat resistance, particularly in applications involving human contact, such as food packaging.

Innovation Solution

A process involving the use of light-curable silicone compositions, which are cured at low temperatures (0-50°C), allowing for the combination with thermoplastics in injection molding without the need for high-temperature crosslinking, thus eliminating the need for transparent molds and reducing energy consumption.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If conventional two-component injection molding with heat-curable elastomers is used, then composite molded bodies can be produced, but multiple heating steps are required which is energetically unfavorable

Engineering Contradiction:

Improvecomposite molded body productionVSAvoidenergy consumption

Core Design Contradiction:

Ease of manufactureVSUse of energy by moving object

Solution Approach 1:

The patent changes the curing mechanism parameter from thermal curing (requiring heating above 120°C) to photopolymerization curing (using UV light at room temperature). This parameter change eliminates the need for multiple heating steps while maintaining the ability to produce composite molded bodies, directly resolving the energy consumption issue.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent replaces the thermal field (heat) with an optical field (UV light) to initiate the curing process. This substitution eliminates the need for heating equipment and multiple thermal cycles, reducing energy consumption while achieving the same manufacturing objective of producing composite molded bodies.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If thermoplastics with high heat resistance are used, then crosslinking temperature can be maintained below softening temperature, but the spectrum of available materials is limited

Engineering Contradiction:

Improveheat resistanceVSAvoidmaterial selection range

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

By replacing thermal curing with photopolymerization curing, the patent decouples the curing process from high-temperature requirements. This allows the use of thermoplastics with low heat resistance (below 120°C) while still achieving successful composite molded body production, significantly expanding material selection range.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the curing initiation method from thermal to optical, allowing low-melting-point thermoplastics to be used without compromising the integrity of the composite structure. This parameter change enables access to a broader spectrum of materials including cost-effective, low-heat-resistance thermoplastics.

Inventive Principle:

Principle #35Parameter changes

3Ease of manufacture

If transparent molds are used for light curable silicone composition, then UV irradiation can occur, but the transparent elements are subject to unwanted ageing processes

Engineering Contradiction:

Improvelight curable silicone composition processingVSAvoidmold durability

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent extracts the UV-curing step from the molding process by using transparent inserts that are already in place during injection molding. The UV irradiation occurs after molding, eliminating the need for transparent mold elements throughout the entire process, thus avoiding their ageing issues.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent performs the UV irradiation step after the injection molding is complete. By sequencing the operations this way, the mold elements are not exposed to UV light during molding, preventing ageing, while still enabling the light-curable silicone composition to be processed effectively.

Inventive Principle:

Principle #10Preliminary action

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 process enables the production of composite molded bodies using low-melting thermoplastics, expanding the range of available materials, and allows for the use of more sustainable alternatives, while reducing energy costs and extending the application of these materials to food containers and drinking water installations.

Implementation Method 1

Irradiating the light curable silicone composition with light of a wavelength suitable for curing the silicone composition

Methodology Applied

Scientific EffectPhotopolymerization: Photopolymerisation

Data Source

PatentUS10384382B2Process for the preparation of plastic composite molded bodies

Publication Date: 2019.08.20 MOMENTIVE-PERFORMANCE MATERIALS GMBH

AI summary

Process for the preparation of plastic composite molded bodies in which hard-soft molded bodies made of low-melting thermoplastics and light curable polyorganosiloxane compositions are prepared as well as products produced by this process.