Organic-Inorganic Hybrid Polymer Coatings via Base-Catalyzed Michael Addition
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Solution Overview
Problem
Conventional UV-curing technologies face limitations such as oxygen inhibition, volume shrinkage, and poor adhesion, which hinder their widespread commercial use in coatings and additive manufacturing, particularly due to the use of acrylate monomers with toxicity concerns.
Innovation Solution
A method for forming an organic-inorganic hybrid (OIH) polymeric composition through a UV-curable composition comprising Michael-addition (MA) acceptor and donor compounds, a silane compound with hydrolysable groups, and a photo-latent base initiator, which undergoes base-catalyzed polymerization and condensation reactions to form a crosslinked network, eliminating the need for continuous UV radiation and reducing toxicity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional UV-curing technology using acrylate monomers is used, then rapid curing and VOC-free composition are achieved, but oxygen inhibition, volume shrinkage, poor adhesion, and toxicity occur
Solution Approach 1:
The patent changes the chemical parameters of the curing system by replacing acrylate monomers with Michael addition acceptor/donor compounds and using a base catalyst instead of free radical initiators. This fundamental parameter change eliminates oxygen inhibition while maintaining rapid curing through the base-catalyzed Michael addition mechanism
Solution Approach 2:
The patent employs a composite curing system combining organic Michael addition chemistry with inorganic silane crosslinking. The silane component undergoes condensation to form an inorganic network that complements the organic Michael addition network, creating a hybrid material that addresses multiple limitations simultaneously including adhesion and mechanical properties
2Productivity
If UV-induced free-radical polymerization is used, then rapid curing is achieved, but substantial volume shrinkage and poor adhesion occur
Solution Approach 1:
The patent changes the polymerization mechanism from free-radical to base-catalyzed Michael addition. This parameter change fundamentally alters the reaction pathway to proceed with minimal volume shrinkage and improved adhesion while maintaining the rapid curing characteristic through efficient base catalysis
Solution Approach 2:
The patent incorporates silane compounds with hydrolysable groups that undergo preliminary hydrolysis and condensation to form an inorganic network structure before or during the Michael addition curing. This preliminary action creates a stable framework that reduces overall volume shrinkage and enhances adhesion properties
3Ease of manufacture
If acrylate monomers are used as reactive diluents, then UV-curing is achieved, but toxicity concerns arise
Solution Approach 1:
The patent replaces acrylate monomers with Michael addition acceptor/donor compounds that have lower or no toxicity. This parameter change in the chemical composition eliminates the harmful effects of acrylate toxicity while preserving the UV-curing capability through the base-catalyzed Michael addition mechanism
Solution Approach 2:
The patent uses silane compounds as reactive diluents instead of acrylate monomers. The silane components serve the dual purpose of dilution and network formation through condensation, eliminating the need for separate toxic acrylate monomers while maintaining formulation flexibility and UV-curing functionality
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 approach eliminates the limitations of conventional UV-curing systems by providing a cross-linked polymer network with tunable properties, improved adhesion, and reduced toxicity, suitable for use in coatings and additive manufacturing, while maintaining low viscosity and better film properties.
Implementation Method 1
exposing the UV-curable composition to UV radiation (i) to form a base catalyst from the photo-latent base initiator
Implementation Method 2
catalyze with the base catalyst (A) MA polymerization between MA acceptor functional groups and MA donor functional groups
Implementation Method 3
condensation of silanol groups formed from hydrolysis of the hydrolysable groups
Implementation Method 4
hydrolysis of the hydrolysable groups
Data Source
AI summary
The disclosure relates to an organic-inorganic hybrid (OIH) polymeric composition and related methods for forming the same. The disclosure also relates to a polymeric composition as disclosed herein and related methods for forming the same. The OIH polymeric composition and the polymeric composition can be formed by UV-irradiating a corresponding composition including a Michael-addition (MA) acceptor compound, a Michael-addition (MA) donor compound, a silane compound, when present, and a photo-latent base initiator to form a corresponding base catalyst and catalyze the reactions forming the networked polymer. The OIH polymeric composition and the polymeric composition can be used as a coating on any of a variety of substrates or as an interlayer in an additive manufacturing process.