UV-Curable Polymer Components with Light Transmitting Elements
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Solution Overview
Problem
Traditional polymer curing methods, such as heat and solvent-based processes, result in shrinkage and residual stresses in fiber-reinforced polymers, leading to potential matrix cracking and anisotropic material performance, while ultraviolet curable polymers face challenges in curing thicker components due to limited light penetration.
Innovation Solution
Incorporating light transmitting elements, such as optic fibers or coated reinforcing fibers, to distribute ultraviolet light within the polymer component, and using ultraviolet light source precursors triggered by heat or vibration to facilitate local curing, allowing for reduced shrinkage and controlled curing processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional heat or solvent-based curing methods are used, then the polymer can be cured, but shrinkage and residual stresses occur leading to matrix cracking and anisotropic performance
Solution Approach 1:
The patent replaces thermal and chemical curing mechanisms with ultraviolet light-based curing. Instead of using heat (thermal energy) or solvent evaporation (chemical process) to cure the polymer, the invention employs UV light irradiation which causes photopolymerization of the resin system, eliminating the shrinkage and residual stress problems associated with traditional curing methods
Solution Approach 2:
The invention changes the curing parameter from thermal/chemical to optical. By selecting specific UV wavelengths and exposure durations, the polymer cures without the molecular rearrangements that cause shrinkage in traditional processes. The resin composition is also modified to include photoinitiators and UV-curable monomers that enable this parameter change
2Manufacturing precision
If ultraviolet light is applied to cure the polymer, then shrinkage is minimized, but thicker components cannot be cured due to limited light penetration
Solution Approach 1:
The patent segments the UV light delivery system by incorporating multiple light sources within the component structure itself. Optical fibers or light-transmitting elements are distributed throughout the polymer matrix, dividing the single curing operation into multiple localized curing zones that collectively cure the entire thick component uniformly
Solution Approach 2:
The invention transitions from surface-based UV curing (two-dimensional exposure) to volumetric curing by embedding light sources within the three-dimensional structure of the component. This allows UV light to be delivered from multiple spatial dimensions simultaneously, enabling complete penetration and curing of thick sections
3Strength
If opaque fibers are used for reinforcement, then structural strength is improved, but ultraviolet light cannot penetrate to cure the polymer at significant depths
Solution Approach 1:
The patent introduces light-transmitting elements as intermediaries between the UV light source and the polymer matrix. These elements (optical fibers, light guides, or transparent reinforcement materials) carry UV light through the opaque fiber-reinforced structure to regions that would otherwise be inaccessible, enabling curing without compromising structural strength
Solution Approach 2:
The invention makes the reinforcement structure multi-functional by selecting fiber types or coating materials that can both provide structural strength and transmit UV light. Some fibers are coated with UV-transmissive materials or selected from materials that are transparent to UV wavelengths, allowing them to serve dual purposes of reinforcement and light conduction
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 approach minimizes shrinkage and residual stresses, enables curing of thicker components, and maintains structural integrity by ensuring uniform or localized curing of ultraviolet curable polymers, while avoiding the use of solvents and high temperatures.
Implementation Method 1
utilizing ultraviolet curable polymers and resins
Implementation Method 2
Incorporating light transmitting elements, such as optic fibers or coated reinforcing fibers, to distribute ultraviolet light within the polymer component
Data Source
AI summary
Conventional curable polymers tend to shrink upon curing whilst low shrinkage ultraviolet light curing polymers have a problem with respect to curing below surface areas of a component. By providing light transmitting elements and/or local ultraviolet light source precursors, greater depth of ultraviolet curing can be achieved and therefore enhanced acceptability with regard to component manufacture. The light transmitting elements may be formed by optic fibers or coatings to existing reinforcing fibers or through consideration of the refractive index of the cured and uncured polymer to create light transmission paths through the component. Ultraviolet light source precursors can be activated by heat or a “seed” light exposure or vibration to create localised ultraviolet curing of the polymer thereabout.