Solvent-Free UV Curing Polymer via Triethanolamine Acceleration

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Solution Overview

Problem

Existing polymer production methods face challenges such as insufficient heat transfer, high viscosity, solvent usage that dilutes the polymerization medium, high energy requirements for curing, and susceptibility of photo-initiators and monomers to medium conditions, leading to increased costs and inefficiencies.

Innovation Solution

A polymer material is produced using a UV curing process with lithium phenyl-2,4,6-trimethylbenzoylphosphinate as the photo-initiator, pentaerythritol triacrylate as the monomer, and electron donor triethanolamine as the co-initiator, with 1-vinyl-2 pyrrolidinone as an accelerator, which forms cross-bonds under low energy UV light, reducing curing time to 1-2 seconds and eliminating solvent use.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If solvent is used for polymerization processes, then viscosity of polymerization medium decreases, but removal of solvent becomes costly and difficult

Engineering Contradiction:

Improveviscosity controlVSAvoidsolvent removal cost

Core Design Contradiction:

Ease of manufactureVSLoss of substance

Solution Approach 1:

The patent extracts and eliminates the solvent component from the polymerization system entirely. By using a solvent-free formulation with carefully selected monomers and photo-initiators, the invention removes the harmful substance (solvent) while maintaining workable viscosity through molecular structure design rather than solvent addition.

Inventive Principle:

Principle #2Taking out (Extraction)

2Reliability

If high energy light source is used for curing, then polymerization can be achieved, but curing process cost increases

Engineering Contradiction:

Improvecuring capabilityVSAvoidlight source energy consumption

Core Design Contradiction:

ReliabilityVSUse of energy by moving object

Solution Approach 1:

The patent changes the chemical parameters of the photo-initiator system to match lower energy UV wavelengths. By selecting photo-initiators with appropriate absorption spectra and using co-initiator systems, the invention enables effective curing with low energy UV light sources, transforming the energy parameter requirements from high to low while maintaining curing reliability.

Inventive Principle:

Principle #35Parameter changes

3Productivity

If photo-initiators and monomers are used, then polymerization can proceed, but they are susceptible to medium conditions and deteriorate rapidly

Engineering Contradiction:

Improvepolymerization capabilityVSAvoidstability under medium conditions

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The patent creates a composite photo-initiator system combining multiple components (photo-initiator + co-initiator + accelerator) that work synergistically. This composite approach enhances stability under medium conditions while maintaining polymerization capability, as each component compensates for the weaknesses of the others regarding susceptibility to environmental factors.

Inventive Principle:

Principle #40Composite materials

4Productivity

If rapid curing is achieved, then production efficiency increases, but heat transfer becomes insufficient

Engineering Contradiction:

Improvecuring speedVSAvoidheat transfer efficiency

Core Design Contradiction:

ProductivityVSTemperature

Solution Approach 1:

The patent uses partial action by initiating polymerization at multiple points simultaneously through the photo-initiator system activated by UV light. This distributed initiation approach allows rapid curing throughout the material volume without generating excessive localized heat that would overwhelm heat transfer capabilities, thereby achieving fast curing while managing thermal effects.

Inventive Principle:

Principle #16Partial or excessive action

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 method achieves rapid curing of polymers with low energy consumption, reduces solvent-related issues, and enhances stability against medium conditions, enabling efficient production and application in 3D printing and other applications with improved cost-effectiveness and environmental sustainability.

Implementation Method 1

UV rays are used for initiating polymerization. The reaction formed by UV rays provides transformation of a liquid system into a solid system having characteristics like rubber or glass at room temperature and within a few seconds.

Methodology Applied

Scientific EffectPhotopolymerization: Photopolymerisation

Implementation Method 2

Photo-polymers are activated in lights with different wavelengths with respect to their types. Moreover, the amount of energy, to which is being subjected depending on the power and duration of light, changes the cure level.

Methodology Applied

Scientific EffectPhoto-initiation: Photopolymerisation

Data Source

PatentUS12103989B2Production of polymeric material which can be cured rapidly by means of the effect of ultraviolet (UV) rays

Publication Date: 2024.10.01 BAHCESEHIR UNIVERSITY

AI summary

A production of polymer material realized at low energy and with rapid curing process for providing advantages mentioned in the specification. The polymer material is aimed to be used as a resin material for three-dimensional (3D) printers and as a filling substance to be added into another material for increasing hardness, as a nano/micro-particle production material, as an ink for printing, and as a press, mold and surface coating material.