Photoactive Resins for Fast UV Curing and Low Migration
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Solution Overview
Problem
Radiation curable compositions face challenges with migration issues due to low molecular weight photoinitiators, leading to odor and toxicity problems in packaging applications, and require improved curing properties for faster processing and reduced production costs.
Innovation Solution
The development of novel photoactive resins with aromatic ketone monomers and amines, which form radiation curable compositions that reduce the need for low molecular weight photoinitiators and enhance curing speed by promoting fast polymerization with UV light, thereby minimizing migration and improving cure performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If low molecular weight photoinitiators are used to initiate polymerization, then curing speed is improved, but migration and toxicity problems occur
Solution Approach 1:
The patent removes the harmful low molecular weight photoinitiators from the formulation and replaces them with high molecular weight photopolymerizable compounds that do not migrate. This extraction of the harmful component resolves the contradiction by maintaining curing functionality while eliminating migration and toxicity issues.
Solution Approach 2:
The patent changes the molecular weight parameter of the photoinitiator from low (causing migration) to high (preventing migration). By adjusting this critical parameter, the system achieves both fast curing and non-migrating properties, resolving the technical contradiction between speed and safety.
2Reliability
If conventional photoinitiators are used, then polymerization can be initiated, but production time increases due to slower curing
Solution Approach 1:
The patent modifies the photopolymerizable compound parameters to include high molecular weight compounds with enhanced photoreactivity. This parameter change enables both reliable polymerization initiation and accelerated curing speed, reducing production time while maintaining reliability.
3Object-generated harmful factors
If high molecular weight photopolymerizable compounds are used, then migration is reduced, but curing speed decreases
Solution Approach 1:
The patent creates a composite system combining high molecular weight photopolymerizable compounds with specific catalysts and photoinitiators. This composite formulation maintains the non-migrating property of high molecular weight compounds while achieving fast curing speed through synergistic interactions between components.
Solution Approach 2:
The patent introduces catalysts and photoinitiators as intermediary substances that mediate between the high molecular weight photopolymerizable compounds and the curing process. These intermediaries enable fast curing to occur even with high molecular weight compounds that would otherwise cure slowly, resolving the speed-migration contradiction.
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 novel photoactive resins enable faster curing with lower UV doses, reducing migration and toxicity concerns, and provide superior cure performance in various applications, including food packaging, while minimizing the use of low molecular weight photoinitiators.
Implementation Method 1
The chemical reaction generally is initiated by a radiation source such as ultraviolet light or high-energy electron beams... initiate free radical polymerization of the acrylate
Implementation Method 2
The resin includes an aromatic ketone monomer including a biphenyl moiety... photoinitiators having a molecular weight less than 500 Daltons are susceptible to migration resulting in odor and toxicity problems
Data Source
AI summary
The present invention is directed to photoactive resins employed in radiation curable compositions and ink. The radiation curable compositions include mono or multi-functional acrylates, an amine and the above-mentioned photoactive resin. Radiation curable inks at least include the components of the radiation curable composition in addition to colorants.