UV-Cured Fastener Sealing Material for Miniature Fasteners
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Solution Overview
Problem
Existing sealing materials for fasteners, particularly miniature and sub-miniature fasteners, face challenges such as high rejection rates due to overspray issues, inadequate temperature resistance, and inability to maintain sealing properties during repeated installations and removals, especially in applications requiring high adhesion and durability.
Innovation Solution
A liquid-applied acrylate-based sealing material, such as acrylated urethane, cured using ultraviolet or LED light without heat, with additives like super hydrophobic materials and photoinitiators, offering low viscosity for easy application and rapid curing, ensuring effective sealing and durability across multiple cycles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If powder sealing material is applied to miniature and sub-miniature fasteners, then sealing coverage is improved, but rejection rate increases due to overspray issues
Solution Approach 1:
The patent changes the physical state of the sealing material from powder to liquid form. This parameter change allows the material to be applied as a liquid coating that can be precisely controlled, eliminating the overspray issues inherent in powder application while maintaining complete sealing coverage on miniature and sub-miniature fasteners.
Solution Approach 2:
The patent replaces the thermal curing mechanism (heating to melt powder) with a chemical curing mechanism (UV light activation). This substitution eliminates the need for high-temperature heating that causes powder to fly off small fasteners, while still achieving complete curing and sealing. The UV-curable liquid formulation allows precise application without the mechanical ejection problems of heated powder.
2Reliability
If heat is applied to cure sealing material, then curing is achieved, but fastener head finish deteriorates due to discoloration
Solution Approach 1:
The patent replaces thermal energy (heat) with electromagnetic energy (UV light) for the curing process. This substitution allows the sealing material to cure effectively without subjecting the fastener head to high temperatures that cause discoloration and finish deterioration. The UV-curable chemistry enables curing at ambient temperatures while maintaining the aesthetic appearance of the fastener.
3Reliability
If preformed resilient washers are used for sealing, then sealing is provided, but temperature resistance and physical integrity are insufficient
Solution Approach 1:
The patent uses a composite formulation consisting of UV-curable acrylic resin combined with heat-resistant additives. This composite material provides both the sealing function of resilient materials and the temperature resistance required for automotive applications. The chemical cross-linking structure of the cured acrylic provides thermal stability while maintaining elastomeric sealing properties, eliminating the temperature limitations of conventional silicone and rubber washers.
4Ease of operation
If liquid applied sealant is used, then application ease is improved, but curing time increases without rapid UV curing
Solution Approach 1:
The patent employs periodic UV light exposure to cure the liquid sealant. Instead of requiring long periods for natural evaporation or slow thermal curing, the UV light provides periodic energy pulses that rapidly initiate and complete the photopolymerization reaction. This periodic electromagnetic energy input transforms the curing process from a slow passive process to a rapid active process, maintaining application ease while dramatically reducing curing time.
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 solution provides a reliable seal against water, moisture, and dust, with superior adhesion and durability, maintaining sealing properties even after multiple installations and removals, and withstanding high temperatures, thus addressing the limitations of existing materials.
Implementation Method 1
The liquid applied material is cured using an ultraviolet or LED light source and without the use of heat
Implementation Method 2
A super hydrophobic material can be included as an additive
Data Source
AI summary
A fastener sealing material for application to fasteners is formulated from an acrylate present in a concentration of about 90 to about 97 percent by weight of the sealing material and a nanostructured material present in a concentration of about 3 to about 10 percent by weight of the sealing material. The sealant is applied to the fastener as a liquid and is cured using an ultraviolet or LED light source and without the use of heat.