Silicone Lamination Process for Bubble-Free Room-Temperature Curing

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Solution Overview

Problem

Existing lamination processes for rigid substrates, such as glass, require high temperatures and pressures, leading to material degradation, bubble formation, and poor light transmission, especially when using silicone-based adhesives that release volatile by-products during condensation curing.

Innovation Solution

A process involving a dam of sealant around the periphery, application of a silicone lamination adhesive, vacuum, and repeated pressure release to ensure a continuous adhesive layer without bubbles, using condensation-curable silicone compositions with specific catalyst ratios to cure at room temperature.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If condensation curing silicone compositions are used as lamination adhesives, then room temperature curing is achieved, but volatile by-products are released causing bubble formation

Engineering Contradiction:

Improvecuring temperatureVSAvoidbubble formation

Core Design Contradiction:

TemperatureVSObject-generated harmful factors

Solution Approach 1:

The patent applies vacuum pressure cycles to remove the harmful volatile by-products released during condensation curing. The vacuum phase extracts the bubbles and volatiles, while the pressure phase ensures proper bonding, converting the harmful bubble-forming reaction into a beneficial room temperature curing process that produces clear, bubble-free laminates

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

The patent creates a controlled vacuum environment during the lamination process to exclude air and prevent additional bubble formation. The vacuum condition provides an inert atmosphere that allows the volatile by-products to be removed without introducing new contaminants or interfering with the curing chemistry

Inventive Principle:

Principle #39Inert atmosphere (Inert environment)

2Strength

If high temperature processing is used for lamination, then adhesion is improved, but material degradation occurs

Engineering Contradiction:

Improveadhesion strengthVSAvoidmaterial stability

Core Design Contradiction:

StrengthVSStability of the object's composition

Solution Approach 1:

The patent fundamentally changes the temperature parameter from high temperature (conventional lamination) to room temperature (condensation curing), and compensates for the reduced thermal energy by using vacuum pressure cycles and extended processing time to achieve equivalent or superior adhesion without material degradation

Inventive Principle:

Principle #35Parameter changes

3Speed

If addition cure silicone compositions are used, then fast curing is achieved, but elevated temperature processing is required

Engineering Contradiction:

Improvecuring speedVSAvoidprocessing temperature

Core Design Contradiction:

SpeedVSTemperature

Solution Approach 1:

The patent changes the curing chemistry from addition cure (requiring heat) to condensation cure (room temperature), accepting slower curing speed in exchange for eliminating elevated temperature processing. The vacuum pressure cycles help accelerate the apparent curing rate by removing volatiles and promoting complete reaction

Inventive Principle:

Principle #35Parameter changes

4Manufacturing precision

If repeated vacuum and pressure cycles are applied, then bubble-free laminates are achieved, but processing time increases

Engineering Contradiction:

Improvebubble-free qualityVSAvoidprocessing time

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

The patent employs periodic vacuum and pressure cycles instead of continuous processing. The alternating phases allow volatiles to be drawn out during vacuum periods and the laminate to consolidate during pressure periods, achieving bubble-free quality through rhythmic rather than continuous action, which is more efficient than sustained high-pressure processing

Inventive Principle:

Principle #19Periodic 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 produces bubble-free, durable laminates with improved light transmission, suitable for temperature-sensitive components, requiring low capital investment and enabling higher throughput without the need for autoclaves or heating.

Implementation Method 1

applying a vacuum to the pre-cured assembly of step (iii)

Methodology Applied

Scientific EffectVacuum: Vacuum

Implementation Method 2

pressing the pre-cured assembly of step (iv) at a pre-determined pressure

Methodology Applied

Scientific EffectCompression: Compression

Implementation Method 3

condensation cure systems... they release volatile by-products during the condensation cure process

Methodology Applied

Scientific EffectCondensation cure: Condensation

Data Source

PatentEP3621803B1Lamination process, product and use

Publication Date: 2025.11.26 DOW SILICONES CORP

Figure 1A~1B
Figure 2

AI summary

A lamination process for silicone based lamination adhesive compositions, in particular those which cure at or around room temperature.