UV-Curable Optical Agent Encapsulation for Complex Substrates
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Solution Overview
Problem
Existing methods for applying optical agent films to substrate surfaces are expensive and limited by substrate dimension, shape, and composition, necessitating a more cost-effective and standardized application methodology.
Innovation Solution
A method for encapsulating a composite resin-filler system containing optical agents, using a UV-curable hydrophobic resin mixture with a metal oxide material, forming an ultrathin layer that can be applied to substrates and ruptured on demand to release the optical agent mixture, which is then UV-cured.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional spraying, dip-coating, CVD, or ALD methods are used to apply optical agent films, then the films can be deposited on substrate surfaces, but the processes become expensive and limited by substrate dimension, shape, and composition
Solution Approach 1:
The optical agent film is segmented into discrete encapsulated beads containing optical agents, which can be applied individually or in collections to substrate surfaces. This segmentation allows the film to conform to complex shapes and dimensions while simplifying the application process through standardized bead units.
Solution Approach 2:
The patent changes the physical state and delivery mechanism of optical agents from continuous film deposition to discrete encapsulated beads. This parameter change enables application to substrates of various dimensions, shapes, and compositions without requiring specialized equipment for each substrate type.
2Quantity of substance
If encapsulation shell thickness is reduced to achieve ultrathin layers, then material usage is minimized, but encapsulation efficiency and protective barrier function may be compromised
Solution Approach 1:
The encapsulation shell is formulated as a composite material combining UV-curable resin with hydrophobic components and metal oxide fillers. This composite structure achieves both ultrathin dimensions and sufficient mechanical strength/protection, as the metal oxide particles provide structural reinforcement while the hydrophobic components enhance barrier properties.
Solution Approach 2:
The patent employs flexible thin film encapsulation shells that can be cured to different degrees (partially or fully) to achieve the desired balance between protection and material usage. The thin film structure allows conformal coating on complex substrate geometries while maintaining integrity.
3Productivity
If the encapsulation shell is made thinner to form ultrathin layers, then the coating is more efficient, but the structural integrity and protection during transport may be reduced
Solution Approach 1:
The encapsulation shell exhibits local quality variations through its composite structure, with metal oxide particles providing localized reinforcement points within the thin resin matrix. This allows the shell to maintain structural integrity at ultrathin overall dimensions, as the reinforced regions bear mechanical loads while the bulk remains thin for efficiency.
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 method enables efficient, controlled delivery of optical agents to substrates with high encapsulation efficiency, reducing material waste and labor costs, and providing a protective barrier for the optical agents during transport and application.
Implementation Method 1
directing UV light from a UV light source to the UV-curable hydrophobic resin mixture bead in the aqueous solution, with the UV light having a selected UV wavelength ranging from about 315 nm to about 400 nm, and at least partially UV-curing the UV-curable hydrophobic resin mixture bead outer surface
Data Source
AI summary
An encapsulation and methods for encapsulating a UV-curable resin-filler system content containing optical agents and delivering to a substrate an encapsulated UV-curable resin-filler system containing optical agents, to form a UV-curable and UV-cured layer that can be an ultrathin layer comprising an optical agent mixture released from ruptured encapsulations.