Silicone Optical Element Printing for High Heat Stability
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Solution Overview
Problem
Existing methods for printing optical elements using droplet-on-demand inkjet technologies result in structures with low heat stability, making them unsuitable for light sources that generate significant heat, as polymer-based inks can melt under high heat energy.
Innovation Solution
A method involving the ejection and curing of silicone-based droplets onto a substrate, utilizing a mixture of silicone and acrylics with controlled viscosity and UV or infrared curing, which enhances the thermal resistance of the printed optical elements to withstand temperatures up to 250°C.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If polymer-based printing ink is used for printing optical elements, then the printing process is simple and conventional, but the heat stability of the printed structures is low and they melt under high heat energy
Solution Approach 1:
The patent changes the chemical composition parameter of the printing ink from conventional polymer-based materials to silicone-based materials. This parameter change fundamentally alters the thermal properties of the printed optical elements, enabling them to withstand temperatures up to 250°C while maintaining printability through controlled viscosity ranges (5-12 centipoise).
Solution Approach 2:
The patent employs composite printing materials that combine silicone with acrylics and epoxy modifiers to create a multi-component system. This composite approach allows the ink to exhibit both the desired high thermal resistance of silicone and the printability/curing characteristics of conventional polymer inks, resolving the contradiction between heat stability and ease of manufacture.
2Temperature
If silicone-based printing material is used to achieve high heat stability, then the thermal resistance increases to withstand 250°C, but the viscosity control and curing process complexity increases
Solution Approach 1:
The patent incorporates preliminary heating of the silicone-based printing material to at least 75°C, preferably at least 100°C, and particularly preferably at least 150°C before and/or during ejection. This preliminary action ensures the material achieves the optimal viscosity range for inkjet printing, preventing clogging and ensuring smooth deposition while maintaining the high thermal resistance properties of silicone.
Solution Approach 2:
The patent employs periodic or multi-stage curing processes including UV irradiation, infrared irradiation, and heat treatment at different stages. This periodic action allows progressive curing of the silicone-based material, ensuring complete polymerization and achieving the desired thermal resistance while managing the complexity through structured, sequential processing steps.
3Manufacturing precision
If the printing material is heated to high temperatures before ejection to achieve proper viscosity, then the droplet ejection quality improves, but the energy consumption and risk of premature curing increases
Solution Approach 1:
The patent applies preliminary heating of the printing material to temperatures of at least 75°C, preferably at least 100°C, and particularly preferably at least 150°C before ejection. This preliminary action optimizes the viscosity for droplet formation and ejection quality. The heating is controlled and localized to minimize energy consumption and prevent premature curing through immediate deposition onto the substrate.
Solution Approach 2:
The patent employs rapid heating and immediate ejection of the heated material, skipping the intermediate state where the material would cool down or cure prematurely. This rushing through the heating process ensures the material maintains optimal viscosity during ejection while minimizing total energy exposure and preventing unwanted curing before deposition.
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 method produces optical elements with significantly higher heat stability, enabling their use with heat-producing light sources without melting or degradation, while maintaining the flexibility to print complex shapes and forms.
Implementation Method 1
the deposited droplet is cured in the second step by ultraviolet irradiation
Implementation Method 2
the deposited droplet is cured in the second step by infrared irradiation
Implementation Method 3
the printing material of the at least one droplet is heated at least to 75 degree Celsius, preferably at least to 100 degree Celsius and particularly preferably at least to 150 degree Celsius before and/or while ejecting the droplet
Data Source
AI summary
The present inventions refers to a method for printing an optical element (11) comprising the steps of ejecting at least one droplet (6) of printing material comprising silicone towards a substrate (8) in a first step and curing the droplet deposited on the substrate in a second step.