Photocurable Resin Composition for Fuel Cell Sealing

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Solution Overview

Problem

Photocurable resin compositions for fuel cells face challenges in achieving quick curing and strong adhesion to electrolyte membranes, which are difficult to bond, particularly due to the low polarity of polyisobutylene diacrylate and poor photocurability.

Innovation Solution

A photocurable resin composition comprising a polymer with a polyisobutylene backbone containing (meth)acryloyl groups, a photopolymerization initiator, and silicone oligomers or silane compounds with alkoxy and isocyanate groups, which allows for rapid curing under UV irradiation and improved adhesion to electrolyte membranes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If thermosetting resin compositions are used for sealing agents, then gas barrier properties and heat resistance are improved, but process time increases and electrolyte membrane deterioration occurs due to heating

Engineering Contradiction:

Improvegas barrier propertiesVSAvoidprocess time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The patent replaces thermal curing (heat-based chemical reaction) with photocuring (light-based chemical reaction). The sealing agent uses a photopolymerization initiator that activates upon UV irradiation to cure the resin composition, eliminating the need for thermal heating processes while maintaining the crosslinked network structure for gas barrier properties.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the curing activation parameter from temperature (thermal energy) to wavelength (photonic energy). By selecting a photopolymerization initiator sensitive to UV wavelengths and formulating the resin composition with appropriate photoreactive groups, the curing process occurs at ambient temperature under UV irradiation, reducing process time and avoiding thermal deterioration.

Inventive Principle:

Principle #35Parameter changes

2Reliability

If polyisobutylene diacrylate with low polarity is used, then sealability is achieved, but adhesion to various members deteriorates

Engineering Contradiction:

ImprovesealabilityVSAvoidadhesion strength

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The patent formulates a composite sealing agent containing both unmodified polyisobutylene diacrylate (for sealability) and silane-modified polyisobutylene diacrylate or coupling agents (for adhesion). This composite approach allows the non-polar polyisobutylene segments to provide sealing while the polar silane-modified segments provide strong adhesion to various members including the electrolyte membrane.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent introduces silane-modified compounds and coupling agents as intermediary substances between the non-polar polyisobutylene diacrylate and the polar electrolyte membrane surface. These intermediaries have both non-polar regions that interact with the polyisobutylene and polar regions that bond to the membrane, bridging the adhesion gap.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 quick curing and excellent adhesion to electrolyte membranes, enhancing the sealing performance in fuel cells while maintaining low moisture permeability and heat resistance.

Implementation Method 1

a photopolymerization initiator; and one or more compounds selected from the group consisting of silicone oligomers each having one or more alkoxy groups and one or more (meth)acryloyl groups

Methodology Applied

Scientific EffectPhotopolymerization: Photopolymerisation

Implementation Method 2

silicone oligomers each having one or more alkoxy groups

Methodology Applied

Scientific EffectHydrolysis: Hydrolysis

Implementation Method 3

silicone oligomers each having one or more alkoxy groups and one or more (meth)acryloyl groups

Methodology Applied

Scientific EffectCondensation reaction:

Implementation Method 4

silane compounds (silane coupling agents) each having one or more isocyanate groups

Methodology Applied

Scientific EffectUrethane bond formation:

Data Source

PatentUS10840518B2Photocurable resin composition, fuel cell, and sealing method

Publication Date: 2020.11.17 THREE BOND CO LTD

AI summary

The present invention has an object to provide a photocurable resin composition which can be quickly cured by irradiation with active energy rays such as ultraviolet rays and achieves excellent adhesion to an electrolyte membrane having properties difficult to bond. Specifically, provided is a photocurable resin composition containing the following (A) to (C) ingredients: (A) ingredient: a polymer having a polyisobutylene backbone containing a —[CH2C(CH3)2]— unit, the polymer having one or more (meth)acryloyl groups; (B) ingredient: a photo-radical polymerization initiator; and (C) ingredient: one or more compounds selected from the group consisting of silicone oligomers each having one or more alkoxy groups and one or more (meth)acryloyl groups, silicone oligomers each having one or more alkoxy groups and one or more amino groups, and silane compounds each having one or more isocyanate groups.