Energy curable composition and method of using the same

1. A method of using a volatile organic compound (VOC) free low radiant flux UV curable composition, comprising:

providing a composite mold;

applying a mold release material to at least a portion of the composite mold;

arranging a composite material on a surface of the composite mold;

applying a volatile organic compound (VOC) free low radiant flux UV curable composition to the composite material to substantially soak or saturate the composite material;

applying an energy source having a wavelength in a range from about 360 nm to about 420 nm and a radiant flux at the surface of the substantially soaked or saturated composite material of about 100 m W/cm 2 or less to cure the composite material,

wherein the volatile organic compound (VOC) free low radiant flux UV curable composition comprises:

an acrylate monomers/oligomers;

a thiol monomers/oligomers;

a photo initiator; and

a radical inhibitor.

2. The method of claim 1 , wherein the composite material comprises a single layer of composite material.

3. The method of claim 1 , wherein the composite material comprises one or more of a semi-synthetic fiber, a cellulose fiber, a fiberglass fiber, a carbon fiber, synthetic fiber, a metallic fiber, a silicon carbide fiber, a mineral fiber, polymer fiber or a microfiber.

4. The method of claim 1 , wherein the composite material comprises at least one of a synthetic or natural fiber.

5. The method of claim 1 , wherein the composite mold comprises one of a boat haul mold, an aircraft component mold, a windmill blade mold, a part mold, a fishing lure mold, a bathtub mold, a shower stall mold, a swimming pool mold, an automotive part mold, or an airfoil wing type shape mold.

6. The method of claim 1 , wherein the composite mold comprises UV transparent material.

7. The method of claim 1 , wherein the composite mold comprises an autoclave mold.

8. The method of claim 1 , wherein the VOC free low radiant flux UV curable composition further comprises a pigment as a colorant.

9. The method of claim 8 , wherein the VOC free low radiant flux UV curable composition further comprises glass/silica fillers.

10. The method of claim 1 , wherein the radiant flux at the surface of the substantially soaked or saturated composite material is about 25 mW/cm 2 or less.

11. The method of claim 1 , wherein the radiant flux at the surface of the substantially soaked or saturated composite material is about 10 mW/cm 2 or less.

12. The method of claim 1 , wherein the radiant flux at the surface of the substantially soaked or saturated composite material is about 5 mW/cm 2 or less.

13. The method of claim 1 , wherein the VOC free low radiant flux UV curable composition comprises ninety-five (95%) percent solids or greater.

14. The method of claim 1 , wherein the acrylate monomers/oligomers comprises one or more of ethylene glycol di(meth)acrylate, tetraethyleneglycol-di(meth)acrylate, poly(ethylene glycol)dimethacrylates, a condensation product of bisphenol A and glycidyl methacrylate, 2,2′-bis [4-(3-methacryloxy-2-hydroxypropoxy)-phenyl]propane, hexanediol di(meth)acrylate, tripropylene glycol di(meth)acrylate, butanediol di(meth)acrylate, neopentyl glycol di(meth)acrylate, diethylene glycol di(meth)acrylate, triethylene glycol di(meth)acrylate, dipropylene glycol di(meth)acrylate, allyl (meth)acrylate trimethylolpropane triacrylate, tris(2-hydroxy ethyl) isocyanurate triacrylate, tricyclodecane dimethanol diacrylate, or combinations thereof.

15. The method of claim 1 , wherein the thiol monomers/oligomers comprises one or more of ethylene glycol bis(thioglycolate), ethylene glycol bis(3-mercaptopropionate), pentaerythritol tetra(3-mercaptopropionate), trimethylolpropane tris(3-mercaptopropionate), pentaerythritol tetra(2-mercaptoacetate), trimethylolpropane tris(2-mercaptoacetate), 1,6-hexanedithiol, 1,2-benzenedithiol, 1,3-benzenedithiol, isophorone diurethane thiol, and combinations thereof.

16. The method of claim 1 , wherein the photo initiator comprises one or more of 2,2-dimethoxy-1,2-diphenylethan-1-one, bis(2,4,6-trimethylbenzoyl)-phenylphosphineoxide, 1-hydroxy-cyclohexyl-phenyl-ketone, 1-hydroxycyclohexyl benzophenone, trimethyl-benzoyl-diphenyl-phosphine-oxide, or combinations thereof.

17. The method of claim 1 , wherein the radical inhibitor comprises one or more of N-nitrosophenylhydroxylamine, hydroquinone and derivatives, monomethyl ether hydroquinone, benzoquinone, methoxy hydroquinone, tert butyl catechol, phenothiazine, or pyrogallol.

18. The method of claim 1 , wherein the UV curable composition comprises a pigment color.

19. A method of using a volatile organic compound (VOC) free low radiant flux UV curable composition, comprising:

providing a composite mold in a predetermined configuration,

applying a mold release material to at least a portion of the composite mold;

arranging a first composite material on a surface of the composite mold;

applying a volatile organic compound (VOC) free low radiant flux UV curable composition to the first composite material to substantially soak or saturate the first composite material;

applying an energy source having a wavelength in a range from about 360 nm to about 420 nm and a radiant flux at the surface of the substantially soaked or saturated first composite material of about 100 mW/cm 2 or less to cure the first composite material,

wherein the volatile organic compound (VOC) free low radiant flux UV curable composition comprises:

an acrylate monomers/oligomers,

a thiol monomers/oligomers;

a photo initiator;

a radical inhibitor; and

a pigment as a colorant.

20. The method of claim 18 , wherein the composite material comprises at least one of a synthetic or natural fiber.

21. A method of using a volatile organic compound (VOC) free low radiant flux UV curable composition, comprising:

providing a composite mold in a predetermined configuration as one of a boat haul mold, an aircraft component mold, a windmill blade mold, a part mold, a fishing lure mold, a bathtub mold, a shower stall mold, a swimming pool mold, an automotive part mold, and an airfoil wing type shape mold,

applying a mold release material to at least a portion of the composite mold;

arranging a first composite material on a surface of the composite mold;

applying a first volatile organic compound (VOC) free low radiant flux UV curable composition to the first composite material to substantially soak or saturate the first composite material;

applying an energy source having a wavelength in a range from about 360 nm to about 420 nm and a radiant flux at the surface of the substantially soaked or saturated first composite material of about 100 mW/cm 2 or less to cure the soaked first composite material,

wherein the first volatile organic compound (VOC) free low radiant flux UV curable composition comprises:

an acrylate monomers/oligomers;

a thiol monomers/oligomers;

a photo initiator;

a radical inhibitor; and

a pigment as a colorant;

applying a second volatile organic compound (VOC) free low radiant flux UV curable material to the cured first composite material to substantially soak or saturate the second composite material; and

applying an energy source having a wavelength in a range from about 360 nm to about 420 nm and a radiant flux at the surface of the substantially soaked or saturated second composite material of about 100 mW/cm 2 or less to cure the soaked second composite material.

22. The method of claim 18 , wherein the composite material comprises one or more of a semi-synthetic fiber, a cellulose fiber, a fiberglass fiber, a carbon fiber, synthetic fiber, a metallic fiber, a silicon carbide fiber, a mineral fiber, polymer fiber or a microfiber.