Method for using a VOC free low radiant flux LED UV curable composition
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Solution Overview
Problem
Conventional radiation curable compositions require high radiant fluxes for curing, which are hazardous and unsuitable for temperature-sensitive substrates, and often result in tacky coatings due to oxygen inhibition, necessitating nitrogen blankets.
Innovation Solution
A VOC-free low radiant flux LED UV curable composition that can cure in an oxygen environment, using wavelengths between 360 nm to 420 nm and radiant fluxes of 100 mW/cm² or less, forming a tack-free coating within 120 seconds, suitable for temperature-sensitive substrates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high radiant flux is used to cure conventional radiation curable compositions, then curing speed is improved, but temperature-sensitive substrates are damaged and hazardous emissions are generated
Solution Approach 1:
The patent changes the wavelength parameter of the UV light from conventional shorter wavelengths (higher energy) to specifically 360-420 nm (lower energy), and changes the radiant flux parameter from high to low (100 mW/cm² or less). This parameter change allows curing to proceed at lower energy levels that do not damage temperature-sensitive substrates or generate hazardous emissions, while still achieving effective curing through extended exposure time
Solution Approach 2:
The patent uses LED light sources that replicate the necessary UV spectrum (360-420 nm) without producing the harmful high-energy radiation associated with conventional UV sources. The LED technology copies the beneficial curing wavelengths while eliminating the harmful components, achieving a safer alternative that maintains curing effectiveness
2Reliability
If conventional radiation curable compositions are used, then curing is achieved, but oxygen inhibition causes tacky coating requiring nitrogen blanket
Solution Approach 1:
The patent converts the harmful effect of oxygen (which causes inhibition and tackiness in conventional systems) into a beneficial factor by using a low-energy UV system that cures through oxygen permeable substrates without generating significant heat. The lower radiant flux prevents oxygen from interfering with the curing process while still allowing crosslinking to occur, eliminating the need for nitrogen blankets and producing tack-free coatings
Solution Approach 2:
By changing the radiant flux parameter to low levels (100 mW/cm² or less) and the wavelength to 360-420 nm, the patent creates curing conditions where oxygen inhibition is minimized. The extended exposure time at lower energy allows the curing reaction to proceed to completion even in the presence of oxygen, achieving tack-free surfaces without requiring oxygen exclusion
3Object-affected harmful factors
If low radiant flux LED UV curable composition is used, then temperature-sensitive substrates are protected and emissions are reduced, but curing time increases
Solution Approach 1:
The patent maintains continuous curing action by using LED light sources that can operate continuously at low radiant flux without overheating or requiring cooling periods. The extended exposure time is utilized efficiently with continuous irradiation, ensuring complete curing while maintaining the low energy input that protects temperature-sensitive substrates and eliminates emissions concerns
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 enables fast curing of coatings on temperature-sensitive substrates without hazardous emissions, reducing setup and cleanup time, and providing fire retardant, chemically resistant, and non-permeable coatings with improved holdout and reduced material costs.
Implementation Method 1
A VOC-free low radiant flux LED UV curable composition that can cure in an oxygen environment, using wavelengths between 360 nm to 420 nm
Data Source
Figure 1A~1D
Figure 2A~2D
Figure 3A~3B
AI summary
The present invention generally relates to a system and method for using a volatile organic compound (VOC) free low radiant flux LED UV curable composition, and more particularly to unique and novel uses of the composition such as one or two or more of a fire retardant, clear coat, composite material, resin, top coat, improved holdout coating, a sealant coat, and combinations of the same.