UV-Cured PVC Plastisol Formulation for Low-Energy Crosslinking

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Solution Overview

Problem

Existing methods for processing polyvinyl chloride (PVC) plastisols are energy-intensive and generate harmful emissions, such as hydrogen chloride, due to the use of high temperatures.

Innovation Solution

A novel formulation for PVC plastisols that enables photocrosslinking solely using UV light, eliminating the need for reactive monomers and high temperatures, and incorporating a photoinitiator, gelling and melting plasticisers, and a polymer to prevent the formation of toxic HCl.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If high temperature processing is used for PVC plastisol, then crosslinking reaction is achieved, but energy consumption increases and harmful emissions are generated

Engineering Contradiction:

Improvecrosslinking reactionVSAvoidenergy consumption

Core Design Contradiction:

ReliabilityVSUse of energy by moving object

Solution Approach 1:

The patent replaces thermal energy (heat) with optical energy (UV light) to initiate and drive the crosslinking reaction. UV photoinitiators absorb ultraviolet radiation and convert it to chemical energy, triggering crosslinking at ambient or low temperatures, thereby eliminating the need for high-temperature furnaces and reducing energy consumption significantly.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the fundamental processing parameter from temperature to UV light intensity and wavelength. By selecting appropriate photoinitiators with specific absorption spectra and using UV lamps with corresponding wavelengths, the crosslinking reaction is activated under mild conditions, transforming the processing regime from thermal to photonic.

Inventive Principle:

Principle #35Parameter changes

2Reliability

If high temperature processing is used for PVC plastisol, then crosslinking reaction is achieved, but harmful emissions such as hydrogen chloride are generated

Engineering Contradiction:

Improvecrosslinking reactionVSAvoidharmful emissions

Core Design Contradiction:

ReliabilityVSObject-generated harmful factors

Solution Approach 1:

By substituting thermal processing with UV photopolymerization, the patent eliminates the decomposition reactions that occur at high temperatures. The UV-induced crosslinking proceeds through a different chemical mechanism that does not generate hydrogen chloride or other harmful emissions, making the process environmentally friendly.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent converts the previously harmful high-temperature processing condition into a beneficial low-temperature UV curing process. What was once a source of pollution (thermal decomposition) is replaced by a clean photonic process that produces no harmful emissions, turning an environmental liability into an advantage.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

3Reliability

If reactive monomers are used for photocrosslinking, then crosslinking reaction is achieved, but product stability and safety are compromised

Engineering Contradiction:

Improvecrosslinking reactionVSAvoidproduct stability

Core Design Contradiction:

ReliabilityVSStability of the object's composition

Solution Approach 1:

The patent introduces UV photoinitiators as intermediary substances that mediate the crosslinking reaction. These photoinitiators absorb UV light and generate reactive species that trigger crosslinking of the PVC plastisol without requiring the addition of reactive monomers. The photoinitiators decompose into less harmful byproducts, maintaining product stability and safety.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 UV-based processing method significantly reduces energy consumption, minimizes environmental pollution, and enhances safety by eliminating high-temperature processing, while maintaining the stability and cream-like viscosity of the plastisol during storage.

Implementation Method 1

The invention refers to formulation for processing polyvinyl chloride plastisol a product of a photocrosslinking reaction, resulting in polyvinyl chloride plastisol and therefrom a PCW plastisol coating on a substrate using UV crosslinking of the surface

Methodology Applied

Scientific EffectPhotopolymerisation: Photopolymerisation

Data Source

PatentUS20250115723A1Formulation for obtaining photocrosslinked plastisol and method for obtaining photocrosslinking plastisol

Publication Date: 2025.04.10 VITA POLYMERS POLAND SP ZOO

AI summary

Invention refers to formulation for processing polyvinyl chloride plastisol by means of a photocrosslinking reaction, that is, for obtaining polyvinyl chloride plastisol and therefrom a PVC plastisol coating on a substrate using UV crosslinking of the surface.The invention also discloses a method for the photocrosslinking of plastisol. The present invention has a practical utility in manufacturing advertising materials, plastic gaskets, wallpaper, artificial leather, bouncy castles and the like. The composition—formulation for obtaining a photocrosslinked plastisol, according to the present invention, comprises three basic components: PVC—native resin or PVC&AC copolymer or PVC&PVAC copolymer; plasticiser mixture i.e. plasticiser known to contain phosphorus, diisononyl phthalate; photoinitiator: 2,4,6-trimethylbenzoyl diphenylphosphine oxide.