Polymer System UV22 UV Curable Highly Nanosilica Reinforced Epoxy System for Nano Technological Applications by Master Bond

Topics Covered

Introduction
Master Bond UV22: One Component, UV Curable, Highly Nanosilica Reinforced Epoxy System
Advantages of Master Bond UV22
Electrical Insulation Properties of Master Bond UV22
Typical Applications for Master Bond UV22 UV Curable Highly Nanosilica Reinforced Epoxy System
     Optical/LCD/LCP
     Medical
     Electronic
     Bonding/Lamination (Non-Optical)
Important UV System Performance Requirements
With An Emphasis on Innovations
Custom Formulations

Introduction

In the highly competitive climate of today's nanoengineering industry, manufacturers are constantly on the search for new, innovative methods of production and design. Master Bond nano grade UV cure systems serve as a cost effective solution to the advanced adhesive needs of the nano industry. The superiority of these systems lay in their ability to cure in seconds, speeding production and processing times, while maintaining the high performance characteristics of standard epoxy systems.

Get the competitive advantage you need. Master Bond nano grade UV curable bonding, sealing, coating and potting & encapsulation compounds are single component and require no weighing or mixing prior to use. They are designed to eliminate waste, save energy, increase efficiency and improve reliability. Environmentally safe, they emit no volatiles or vapors during cure. In addition, because of their storage stability, pot life issues are essentially eliminated. All this and more make Master Bond UV systems the adhesive of choice for nano engineers in search of high performance solutions.

Master Bond UV22: One Component, UV Curable, Highly Nanosilica Reinforced Epoxy System

Master Bond Polymer System UV22 represents a remarkable technological breakthrough in the utilization of nanotechnology in the formulation of a one component UV curable epoxy for coating, sealing, and encapsulation applications. This nanosilica filled system features superior physical properties, enhanced abrasion resistance, excellent optical clarity along with significantly reduced shrinkage after curing.

The performance properties of UV22 surpass those of similar non-reinforced systems by as much as 50-90%. The cycloaliphatic epoxy resin phase offers superior chemical and physical properties together with improved light stability. The silica phase is comprised of surface modified synthetic silicon dioxide nanospheres of very small size (<50nm) and with a very narrow particle size distribution. Despite the remarkably high percentage of nano particles present in the UV22, it still retains high transparency and a desirably low viscosity without sedimentation. This is due to the stability of the agglomerate-free colloidal dispersion of the reinforcing nanosilica particles in the resin phase.

UV22 cures rapidly using light sources emitting a wavelength with 250-365nm with an energy output of as little as 20-40 milliwatts/cm2 with higher output facilitating a faster cure. It can cure within 5-10 seconds with proper UV curing lamps. The shrinkage upon cure is less than 2%. UV22 can be used over the wide temperature range of -60 to 300°F and will cure in thicknesses up to 1/8th of an inch. Additionally, UV22 has excellent electrical insulation properties, and the viscosity of the UV22 system is adjustable to meet specific requirements.

Unlike many other UV curable products, UV22 is not oxygen inhibited and exhibits a fast cure at ambient temperatures, even in the presence of air. Post-curing the UV22 enhances its temperature resistance profile. Adding heat (200-230°F for 30 minutes) will increase the glass transition temperature to >120°C, higher than traditional UV systems. The post cure is also effective in increasing its chemical resistance to solvents, acids and bases. A specially formulated version called UV22DC is available for dual-curing via UV light at ambient temperatures and/or by application of heat e.g. 80-110°C for approx. 1/2 hour to 1 hour. Dual cure UV's are desirable to cure this product in "shadowed out" areas (a section where UV light is unable to reach the material to be cured).

Advantages of Master Bond UV22

Advantages of Master Bond UV22 highly nanosilica reinforced epoxy system include:

  • Greatly enhanced physical properties including the tensile modulus and tensile strength.
  • Ideal for coating and encapsulation.
  • No filler sedimentation upon storage.
  • Excellent optical clarity with high filler loading.
  • Exceptionally low shrinkage; Low coefficient of thermal expansion.
  • Increased hardness and abrasion resistance.
  • Improved shock and vibration resistance.
  • Significantly enhanced fracture toughness.
  • Superior electrical insulation properties for outdoor as well as indoor exposures.
  • Enhanced chemical and permeability resistance to aggressive liquids and gases.
  • Reduced exotherm during curing.

Table 1: Typical Properties of Master Bond UV22 Coatings

Property
Value
Viscosity, uncured coating, 75°F
3500-6500
Solvents and other volatiles
0 %
Density at 75°F
1.4 gms/ml
Acetone double rubs
>200
Shore hardness D
>80
Elongation
3-4 %
Tensile Strength
>4,600 psi
Tensile Modulus
>500,000 psi
Flexural Strength
4,500 psi
Coefficient of linear expansion
35-40 ppm per °C
Glass transition temperature
>90°C
Glass transition temperature with post cure
>120°C
Water resistance (5 minute post cure at 300°F) 3 months immersion
<1 % weight gain
Refractive index
1.52
Abrasion resistance (steel wool test, 50 cycles) weight change of specimen
10-12mg
Water vapor permeability [gl(m2·d)] 45 um cardboard film
170
Shrinkage
<2 %
Service temperature range
-60 to 300 °F
Shelf life, unopened containers at 75°F
6 months
Available in syringes, pints, quarts, gallons and 5 gallon pails.
 

Electrical Insulation Properties of Master Bond UV22

The electrical insulation properties of Master Bond UV22 are shown in Table 2. This data was obtained on 0.125" thick plaques which had been cured at a rate of 14 feet/min with a 200 watt/inch medium pressure mercury vapor lamp UV source and then aged for one week at room temperature before evaluation. They show that the Master Bond UV22 system exhibits greatly superior electrical insulation resistance characteristics up to 300°F.

Property
Value
Volume Resistivity
<1.5 x 1012
Dielectric Constant, 106, 25°C
3.16
Dielectric Constant, 106, 100°C
3.80
Dielectric Constant, 106, 150°C
3.94
Dissipation Factor, 106, 25°C
0.005
Dissipation Factor, 106, 100°C
0.034
Dissipation Factor, 106, 150°C
0.041

Typical Applications for Master Bond UV22 UV Curable Highly Nanosilica Reinforced Epoxy System

Optical/LCD/LCP

Typical applications of Master Bond UV22 UV Curable Highly Nanosilica Reinforced Epoxy System for optical/LCD/LCP applications include:

  • Bonding glass and plastic fibers to fiber optic connectors and ferrules
  • Optical Replication
  • Coating, potting, or bonding optically clear and/or optically sensitive components and indicators
  • Mounting fiber optics
  • Fiber optic splicing
  • Fiber optic and lens bundling and terminating
  • Lens and prism bonding
  • Encapsulation of detectors
  • Fillet bond where good optical transmission in UV, visible, or infrared range is required
  • Mounting, fixturing, laminating, tacking, bonding, and sealing of borescopes (remote video scopes) and doublets (stacked lenses)
  • YAG Lasers (Yttrium aluminum garnet-synthetic crystalline material. Used in manufacturing, and to mark/cut metals)
  • LCD Laminations
  • Polarizer Laminations
  • LCD Sealant

Medical

Typical applications of Master Bond UV22 UV Curable Highly Nanosilica Reinforced Epoxy System for medical applications include:

  • Needle assembly and bonding (heat exchanger assembly, metal bonding, transducer assembly, potting, bonding connectors)
  • Respiratory devices
  • Breathing mask assembly
  • Tracheotomy tube assembly
  • Resuscitator apparatus
  • Bags for storing liquid contents (drips, IV, saline, waste, etc.)
  • Can be used to fabricate "Form in place" gaskets
  • Catheter bonding, sealing, and assembly
    • Guide wire assembly
    • Bore tube sealing
    • Balloon bonding
    • Sensor attachment
    • Tube joining
    • Catheter hubs
  • Bonding of plastics including PVC & SEBS (styrene-ethylene/butylene-styrene)

Electronic

Typical applications of Master Bond UV22 UV Curable Highly Nanosilica Reinforced Epoxy System for electronic applications include:

  • Encapsulation and coating for environmental protection [shadowed out areas can be cured with heat (double cure)]
  • Glob top
  • Strain relief or chip encapsulation
  • Precision application to specific electronic assembly areas
  • Thin coating, wicking, and underfill
  • Plastic bonding, potting, and sealing
  • Wire tacking and coating
  • Capacitor bonding
  • Chip bonding
  • Tamper-proofing components
  • Prevent coils from unwinding
  • Sealing and potting electrical components
  • HGA (head gimbal assembly) and tamper-proofing

Bonding/Lamination (Non-Optical)

Typical applications of Master Bond UV22 UV Curable Highly Nanosilica Reinforced Epoxy System for bonding/lamination (non-optical) applications include:

  • Polishing
  • Protective coating for abrasion resistance, and water or chemical resistance
  • Crystal assembly
  • Glass laminations/sealing/potting/bonding
  • Bonding metal, steel, and aluminum to glass
  • High peel/cleavage strength for glass and metal bonding
  • Bonding transparent plastics such as acrylics and polycarbonate to various metals
  • Flexible plastic assemblies
  • Flexible and rigid bonding of clear plastics
  • Rapid bonding and sealing of plastics to stainless steel, polycarbonate, and PVC
  • Mirror assembly
  • Bonding glass to thermoset plastics, polycarbonates, acrylics, phenolic, and filled plastics
  • Spin coating UV curables for glass and other substances
  • Glass cationic epoxy and encapsulant
  • Gap filling of non-flat, irregular and handmade glass
  • Bond plastic to ABS, CAP, MBS, PBT, PET, PP, PS, PVC, SAN, Valox, acrylic, brass, ceramic, glass PETG, nylon polyimide, polarized and polyester film, polycarbonate, polystyrene, polyurethane, styrene mylar
  • Wire harness assembly
  • Plastic potting, laminating, and sealing
  • Sealing PVC, PET, A-PET, R-PET clamshell packages
  • Bonding rigid fittings to flexible tubing

Important UV System Performance Requirements

Master Bond UV curable systems are designed to meet specific performance requirements. Among the most important are:

  • Abrasion resistance
  • Chemical resistance
  • Easily polished
  • Easily repairable
  • Electrically insulative
  • Excellent adhesion
  • Dimensional stability
  • Impact resistance
  • Reworkable
  • Screen printable
  • Spectral transmittance
  • Spin coatable
  • Peel strength
  • Optical transmission
  • High temperature resistance
  • Index of refraction
  • Low coefficient of expansion
  • Low outgassing
  • Low shrinkage
  • Low stress
  • Shock resistance
  • Non-yellowing
  • Resistance to water
  • Durability
  • Thermal cycling
  • Vibration resistance

With An Emphasis on Innovations

Recently Introduced UV curable UV10TKLO-2 meets low-outgassing requirements per NASA ASTM E-595, presenting engineers with the rare combination of a UV cure adhesive and low outgassing properties. The UV10TKLO-2 modified epoxy system offers optical clarity, high physical strength properties and good chemical resistance. It is not oxygen-inhibited and cures rapidly at room temperature when exposed to UV light. Maximum UV absorption takes place in the 320- to 365-nm range. It is easy to apply, has high viscosity and can be used in a variety of optical, electro-optical and vacuum applications. Exhibiting good electrical insulation properties, it has a volume resistivity of >1014 Ù cm and a dielectric constant of 3.6 at 60 Hz. Service temperature range is -51 to 149 °C.

Custom Formulations

The many potential applications of nano grade UV cure adhesives make for a very complex selection process; one requiring much research of all relevant considerations. It is for this reason that Master Bond Inc. offers custom formulated solutions, tailor made products possessing the specific properties necessary for successful employment. Regardless of the application requirements, adhesive formulations may be adjusted to possess all required characteristics. The unique line of Master Bond, nano grade UV cure systems may be formulated to withstand the stresses of any hi-tech application, including extreme temperatures, thermal cycling and shock, mechanical forces, vibration, and chemical exposure. Specific adhesive systems can be designed to meet USP Class VI certification for medical use and biocompatibility, and NASA requirements for low outgassing. In addition, specific properties such as viscosity, flexibility, and bond strength are incorporated based on specific application, maximizing system compatibility and performance.

Master Bond Inc. has available a fast growing family of one component UV curable systems. They include polyurethanes, epoxies, polyesters and acrylics. They vary in thicknesses, hardness, chemical resistance, strength, clarity, etc. When exposed to a suitable UV light source, UV curable compounds will cure in a matter of seconds. The Master Bond products are not oxygen inhibited and cure at ambient temperatures. Environmentally friendly, they are 100% reactive liquids which do not contain any solvents or other volatiles. Upon cure they exhibit minimal shrinkage. Additionally, their electrically insulative properties make them especially suitable for microelectronic applications. High Temperature resistant grades are available. With Master Bond's unparalleled experience and expertise, they guarantee the development and successful implementation of a customized solution for your nanoelectronic application.

Source: Master Bond

For more information on this source please visit Master Bond.

Date Added: Jul 14, 2010 | Updated: Jun 11, 2013
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