UV-Curable Epoxy Formulation for High-Voltage 3D-Printed Components
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Solution Overview
Problem
Epoxy formulations based on acrylates for 3D printing of electrical components exhibit inferior properties when subjected to voltage differentials, necessitating improved formulations with enhanced electrical properties.
Innovation Solution
A photo radiation-curable epoxy formulation comprising a photoinitiator, an accelerator, and an epoxy, specifically optimized with 1%-6% photoinitiator, 3%-20% accelerator, and at least 50% epoxy by weight, which can be used in 3D printing to form electrical components with improved glass transition temperature, breakdown strength, and loss factor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If acrylates are used as photoinitiators for quick UV curing in 3D printing, then curing speed is improved, but electrical properties (breakdown strength, loss factor) deteriorate
Solution Approach 1:
The patent changes the chemical composition parameters of the epoxy formulation by replacing acrylate photoinitiators with alternative photoinitiator systems and adjusting the ratios of epoxy resins, hardeners, and additives to achieve both fast curing and superior electrical properties
Solution Approach 2:
The patent creates a composite epoxy formulation combining multiple epoxy resins, hardeners, and photoinitiators in specific proportions to achieve synergistic effects that provide both rapid UV curing capability and enhanced electrical performance for high voltage applications
2Ease of manufacture
If photoinitiators and accelerators are added to enable UV curing, then curing capability is improved, but formulation complexity increases
Solution Approach 1:
The patent merges the functions of photoinitiators, accelerators, and epoxy components into a unified formulation system where multiple ingredients work synergistically to achieve curing through UV exposure while maintaining manageable formulation complexity through optimized component selection and ratios
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 improved epoxy formulation achieves enhanced electrical properties, including a glass transition temperature of at least 120°C, breakdown strength of at least 25 kV/mm, and a loss factor of less than 1%, thereby addressing the inferior performance of existing epoxy/acrylate formulations in electrical components.
Implementation Method 1
the photoinitiator causes curing of the epoxy when photo radiation is applied to the photoinitiator
Data Source
AI summary
An epoxy formulation is provided with improved properties for electrical components exposed to a voltage differential. The improved electrical properties include increased glass transition temperature, increased breakdown strength and/or lower loss factor. Electrical components may be formed from the epoxy formulation by 3D printing the epoxy formulation and curing the formulation with UV radiation. The epoxy formulation includes epoxy, a photoinitiator and an accelerator.