UV-Curable Organopolysiloxane Resin for Optical Components
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Solution Overview
Problem
Existing active energy ray-curable organopolysiloxane resin compositions for optical transmission components face issues with adhesion to substrates, air bubbles in cured films, insufficient shape-retaining properties, and changes in refractive index and optical transmittance upon exposure to elevated temperatures.
Innovation Solution
An active energy ray-curable organopolysiloxane resin composition comprising an epoxy-containing organopolysiloxane resin, a photo acid generator, and a photosensitizer or photo-radical generator, which quickly cures with UV rays, providing superior adhesion, hydrolysis resistance, and solvent resistance, and maintaining optical transmittance and refractive index stability at elevated temperatures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If alkoxy- and epoxy-containing organopolysiloxane is used for radiation curable composition, then adhesion to substrates is improved, but shape-retaining properties and solvent resistance become insufficient
Solution Approach 1:
The patent uses a composite material system combining organopolysiloxane with specific epoxy compounds and condensation catalysts to achieve both adhesion and shape retention. The composite formulation includes controlled ratios of linear/branched polysiloxane, cyclic siloxane, and epoxy compound to balance flexibility and structural integrity.
Solution Approach 2:
The patent optimizes molecular weight parameters (number-average molecular weight 100-1000 for linear polysiloxane, 100-1000 for branched polysiloxane) and compositional ratios (molar ratios of cyclic siloxane to epoxy compound) to achieve the desired balance between adhesion and shape-retaining properties.
2Strength
If condensation based curing is used, then adhesion is improved, but air bubbles are generated in cured films
Solution Approach 1:
The patent extracts and removes air bubbles from the system by incorporating defoaming agents and processing conditions that eliminate bubble formation during curing, while maintaining the condensation-based adhesion mechanism.
Solution Approach 2:
The patent uses defoaming agents as intermediary substances that facilitate the removal of air bubbles during the curing process, allowing condensation-based curing to proceed without generating harmful bubbles in the final film.
3Strength
If epoxy-containing organopolysiloxane is used, then adhesion is improved, but optical transmittance and refractive index stability deteriorate upon exposure to elevated temperatures
Solution Approach 1:
The patent carefully controls the molecular weight parameters and compositional ratios of the epoxy-containing organopolysiloxane to maintain optical stability at elevated temperatures while preserving adhesion properties.
Solution Approach 2:
The patent formulates a composite system with specific ratios of organopolysiloxane, epoxy compounds, and condensation catalysts that collectively provide both adhesion and thermal-optical stability.
4Reliability
If polyimides are used for optical materials, then reliability is improved, but manufacturing complexity and productivity worsen due to high temperature treatment requirements
Solution Approach 1:
The patent replaces the high-temperature mechanical treatment process of polyimides with a chemical curing process using condensation catalysts that operate at lower temperatures, thereby simplifying manufacturing while maintaining reliability.
Solution Approach 2:
The patent changes the curing temperature parameter from high temperature (polyimide requirement) to lower temperature (organopolysiloxane curing), making the manufacturing process simpler and more productive while achieving comparable durability.
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 composition achieves excellent adhesion to substrates, prevents air bubbles, and maintains high optical transmittance and refractive index stability, with improved shape-retaining properties and reduced warpage or cracking, even in thin film form.
Implementation Method 1
an active energy ray-curable organopolysiloxane resin composition which quickly cures with UV rays
Implementation Method 2
irradiating the mixture with light
Data Source
AI summary
An active energy ray (e.g. UV rays)-curable organopolysiloxane resin composition comprises (A) 100 parts by weight of an organopolysiloxane resin containing epoxy groups and aromatic hydrocarbon groups, (B) 0.05 to 20 parts by weight of a photo acid generator, (C) 0.01 to 20 parts by weight of a photosensitizer or photo-radical generator, and (D) 0 to 5,000 parts by weight of an organic solvent. An optical transmission component made of the above-mentioned composition cured by irradiation with active energy rays (for example, UV rays). A method for manufacturing an optical transmission component by irradiating the above-mentioned composition with active energy rays (for example, UV rays).