UV-Curable Filled Coating for Fast Sandable Vehicle Repair
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Solution Overview
Problem
Conventional body filler compositions for vehicle repairs cure too slowly, leading to defects like tacky surfaces, poor adhesion, and long cure times, and existing UV-cured compositions are hazardous and inefficient due to mercury-containing lamps.
Innovation Solution
A UV-curable composition comprising aliphatic urethane acrylate, a multifunctional crosslinking agent, photoinitiator, catalyst, and particulate filler, which cures rapidly under UV-LED exposure, providing a controlled working time and rapid sandability without environmental dependencies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of moving object
If conventional two-part curable resin systems are used, then sufficient working time is provided to shape the composition, but curing time becomes too long and leads to defects like tacky surface, poor adhesion, and blistering
Solution Approach 1:
The patent changes the curing mechanism from conventional two-part chemical curing to UV light-induced photopolymerization. This parameter change enables rapid curing (reducing cure time from hours to minutes) while maintaining cure quality by controlling the photopolymerization reaction through UV exposure duration and intensity, eliminating defects like tacky surfaces and poor adhesion associated with prolonged conventional curing
Solution Approach 2:
The patent replaces the chemical mixing and gradual curing mechanism of two-part resin systems with a physical UV light activation system. The UV-curable composition contains photoinitiators that trigger rapid polymerization upon UV exposure, substituting the gradual chemical reaction of conventional systems with a controllable light-induced reaction that achieves full cure in minutes without the defects of prolonged curing
2Productivity
If UV curing lamps containing mercury are used, then rapid UV cure is achieved, but environmental hazards and operational safety issues arise
Solution Approach 1:
The patent replaces durable but hazardous mercury-containing UV lamps with LED UV curing sources that have shorter operational lifetimes but eliminate environmental hazards. The LED system provides sufficient curing capability for repair applications while being free of mercury, reducing environmental impact and safety concerns associated with lamp disposal and breakage
Solution Approach 2:
The patent eliminates the harmful mercury component from UV curing systems while maintaining the beneficial rapid cure capability. By using LED-based UV sources, the system retains high productivity (fast curing) without the environmental and safety harms of mercury, effectively converting a harmful system into a beneficial one
3Ease of operation
If conventional two-part resin systems are used, then working time can be controlled, but viscosity increases too rapidly requiring repair repetition
Solution Approach 1:
The patent applies preliminary action by providing the entire curing system (photoinitiators, crosslinking agents, and UV-curable resin) in a single pre-mixed composition that remains stable during application. The curing reaction is postponed until UV exposure, allowing extended working time without viscosity increase. This eliminates the need for rapid application and repair repetition required by conventional two-part systems
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 rapid curing within 2-20 minutes, ensuring sandable finish and improved adhesion, reducing rework and environmental hazards associated with mercury-based UV lamps.
Implementation Method 1
UV-curable composition comprising aliphatic urethane acrylate, a multifunctional crosslinking agent, photoinitiator... which cures rapidly under UV-LED exposure
Implementation Method 2
exposure to a UV light source... ultraviolet wavelength emitting light emitting diode (UV LED)
Data Source
AI summary
A composition is provided that includes aliphatic urethane acrylate; a multifunctional crosslinking agent; photoinitiator; a chemical initiator system of a peroxide or azo group containing catalyst, and a cure promoter; and a particulate filler. The composition is amenable to rapid cure to a sandable condition as compared to conventional products. By adjusting the amount of particulate filler present, a product is provided that operates as a primer, a putty, or a filler. A method of vehicle body repair includes the application of an uncured layer of the composition to the vehicle body. The uncured layer is exposed to UV radiation to induce cure of the uncured layer to form a coating in a time of between 2 and 20 minutes even with an ultraviolet wavelength emitting light emitting diode (UV LED).