Water-Based Dielectric Inkjet Fluids for Volatile-Free UV Curing
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Solution Overview
Problem
Conventional UV-curable inkjet compositions for electrical devices contain volatile components that can volatilize during thermal treatments, leading to device failures such as delamination, pinholing, and blistering, and they lack water-based dielectric inkjet compositions with sufficient insulating properties.
Innovation Solution
Inkjet compositions comprising water-soluble or water-dispersible acrylated polyurethane polymers that are polymerizable by free radical polymerization, free of volatile components, and include low amounts of photoinitiators, forming dielectric layers with high breakdown voltage and excellent adhesion to conductive layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional organic solvents (e.g., toluene, xylene) are used in epoxy formulations, then electrical insulation properties and moisture resistance are improved, but environmental safety deteriorates due to toxicity and flammability
Solution Approach 1:
The patent changes the fundamental parameter of the solvent system from organic-based to water-based, achieving a phase transition in the chemical composition. This substitution maintains the necessary insulation properties while eliminating the harmful characteristics of conventional organic solvents like toluene and xylene.
Solution Approach 2:
The patent creates a composite formulation by combining water with epoxy resin and specialized additives. This composite approach allows the water-based system to achieve the performance characteristics traditionally provided by organic solvents, reconciling environmental safety with electrical insulation requirements.
2Object-affected harmful factors
If water-based solvents are used instead of organic solvents, then environmental safety is improved, but electrical insulation properties and moisture resistance deteriorate
Solution Approach 1:
The patent introduces specialized additives as intermediary substances that mediate between the water-based solvent and the epoxy resin. These additives serve as bridging agents that enhance the electrical insulation properties and moisture resistance of the water-based formulation, compensating for the inherent deficiencies of water as a solvent.
Solution Approach 2:
The patent modifies key parameters of the water-based formulation, including pH level, ionic content, and molecular weight distribution of additives, to optimize electrical insulation performance. By carefully controlling these parameters, the formulation achieves insulation properties comparable to or exceeding conventional organic-based systems.
3Reliability
If conventional epoxy formulations are used, then electrical insulation and adhesion are maintained, but production efficiency deteriorates due to extended cure times and sensitivity to moisture
Solution Approach 1:
The patent replaces the conventional moisture-cure or heat-cure mechanism with a radiation-curing mechanism using UV or electron beam energy. This substitution fundamentally changes the curing process from a chemical reaction dependent on environmental moisture or thermal activation to a direct photopolymerization or radiative crosslinking process, dramatically reducing cure time and eliminating moisture sensitivity.
Solution Approach 2:
The patent incorporates photoinitiators or radiation-sensitive groups into the epoxy formulation in advance, preparing the system for rapid curing upon exposure to UV or electron beam radiation. This preliminary incorporation of curing agents enables immediate polymerization upon irradiation, eliminating the extended cure times associated with conventional formulations.
4Productivity
If water-based epoxy formulations are used, then production efficiency is improved through faster curing, but manufacturing complexity increases due to formulation challenges
Solution Approach 1:
The patent designs a self-regulating formulation system where the water-based epoxy automatically maintains optimal pH balance and ionic content through built-in buffer systems and controlled additive packages. This self-service capability reduces the need for complex external control mechanisms and simplifies the manufacturing process despite the sophisticated chemistry involved.
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 compositions provide stable dielectric layers that prevent device failures during thermal treatments, ensuring longer device lifetimes and improved adhesion with conductive layers, suitable for flexible electronic devices.
Implementation Method 1
The components can be UV- or electron-beam-cured, eliminating the need for extended cure times associated with conventional formulations
Implementation Method 2
The components can be UV- or electron-beam-cured
Data Source
AI summary
Water based, energy curable ink jet compositions that have good insulating properties are described herein. The inventive water based energy curable ink jet compositions include a water soluble or water dispersible component polymerizable by free radical polymeration upon exposure to polymerizing radiation, wherein the cured ink jet compositions have good insulating properties, exhibited for example, by its breakdown voltage. Also described are electronic devices including ink jet-printed layers of the ink jet compositions.