A metal corner protector manufacturing process with elastic cushioning and impact protection functions

Abstract

This invention discloses a metal corner protector manufacturing process with elastic cushioning and impact protection functions, relating to the field of metal processing technology. The process includes the following steps: S1, fabricating a metal corner protector based on 65Mn sheet metal material; S2, quenching the metal corner protector; S3, tempering the metal corner protector; S4, applying a plastic coating to the tempered metal corner protector; and S5, filling the metal corner protector with cushioning material. This metal corner protector manufacturing process with elastic cushioning and impact protection functions utilizes 65Mn material to fabricate the metal corner protector and employs heat treatment processes such as quenching to give it strong elasticity, enabling it to cushion external forces on the product. The plastic coating process further enhances its impact resistance and wear resistance. By placing the cushioning material inside the metal corner protector, the impact resistance of the metal corner protector is further strengthened, resulting in better product protection.

Description

Technical Field

[0001] This invention relates to the field of metal processing technology, specifically to a metal corner protector processing technology with elastic buffering and anti-collision functions. Background Technology

[0002] Currently, metal corner protectors (or edge protectors) on the market rely on the strength of sheet metal to prevent breakage. However, because metal corner protectors are very hard and also have burrs, they can easily scratch the product or puncture the packaging when used directly for product or packaging protection. At the same time, metal corner protectors do not provide any cushioning effect against external forces. When the packaged product is dropped, the external force can be transmitted to the product with almost no loss, causing the corners and edges of the product or even other parts to be damaged by violent vibration. It is precisely because of the above defects that metal corner protectors are difficult to use for the protection of most product packaging.

[0003] To address the aforementioned issues, we propose a metal corner protector manufacturing process that provides elastic cushioning and impact protection. Summary of the Invention

[0004] To address the shortcomings of existing technologies, this invention provides a metal corner protector manufacturing process with elastic buffering and anti-collision functions, thereby solving the problems mentioned in the background art.

[0005] To achieve the above objectives, the present invention provides the following technical solution: a metal corner protector processing technology with elastic buffering and anti-collision functions, comprising the following steps:

[0006] S1. Metal corner protectors made from 65Mn sheet metal material;

[0007] S2. Quench the finished metal corner protectors;

[0008] S3. Temper the metal corner protectors to achieve a hardness of HRC48.

[0009] S4. After tempering, the metal corner protectors are coated with plastic to form a 1-2 mm plastic coating on the surface of the metal corner protectors.

[0010] S5. Fill the metal corner protectors with cushioning material.

[0011] To further optimize this technical solution, in step S1, the metal corner protector is made into a metal corner protector with a convex cavity structure having a groove shape.

[0012] To further optimize this technical solution, the metal corner protector includes a corner protector body, which has a convex cavity structure. A groove is formed on the inner surface of the corner protector body, and the cushioning material is filled inside the groove.

[0013] To further optimize this technical solution, the buffer material is a material with good buffering properties, including pearl cotton, EVA, rubber and silicone foam. The buffer material is placed inside the groove by means of adhesion, embedding or polymerization.

[0014] To further optimize this technical solution, in step S2, the quenching process includes:

[0015] The metal corner protector is heated to 850°C to allow the metal grains to grow and change its crystal structure. It is kept at 850°C for 1-2 hours to ensure that the metal corner protector is heated evenly.

[0016] After heating, the metal corner protectors are quickly cooled to room temperature to form a martensitic structure, which is used to increase the hardness of the metal corner protectors.

[0017] Clean the oxides or other contaminants generated on the surface of the quenched metal corner protectors to ensure that the surface of the metal corner protectors is clean.

[0018] To further optimize this technical solution, in step S3, the tempering process includes:

[0019] Heat the quenched metal corner protectors to a temperature range of 200-300℃ and maintain this temperature for 2-3 hours. The tempering time should ensure that the metal corner protectors are fully tempered.

[0020] After tempering is completed, allow the metal corner protectors to cool naturally or control the cooling rate to achieve the preset elasticity and hardness.

[0021] A hardness test was conducted using a Rockwell hardness test to ensure that the metal corner protectors reached the target hardness value of HRC48.

[0022] To further optimize this technical solution, the preset elasticity of the metal corner protector is described by the elastic modulus. The elastic modulus is the ability of a material to undergo elastic deformation under stress. The relationship between the elastic modulus (E) and stress (σ) and strain (ε) is expressed by the following formula:

[0023] [\sigma=E\cdot\varepsilon]

[0024] Where (σ) is stress, measured in Pascals (Pa) or Megapascals (MPa); (E) is the elastic modulus, measured in Pascals (Pa) or Megapascals (MPa); (σ) is stress; and (varepsilon) is strain, which is the deformation per unit length of the material.

[0025] To further optimize this technical solution, step S4, the dip coating process includes:

[0026] Use solvent cleaning, alkaline cleaning, or sandblasting to perform a secondary cleaning on the surface of the metal corner protectors;

[0027] Pre-treatment is performed on the cleaned metal corner protectors;

[0028] Choose PVC or nylon granules or powder as the dip coating material;

[0029] The dip-coating material is heated to its melting temperature to form a molten coating material.

[0030] The pre-treated metal corner protectors are immersed in molten PVC or nylon material. The thickness and uniformity of the dip coating are adjusted by controlling the immersion time and lifting speed to ensure that the entire surface is uniformly coated.

[0031] The coated metal corner protectors are placed in a cooling tank for rapid cooling and curing to form a strong dip-coated layer.

[0032] To further optimize this technical solution, the preprocessing includes:

[0033] The surface of the metal corner protector is sanded to increase its roughness.

[0034] The metal corner protectors are placed in an oven and heated at 100-120℃ for 1-2 minutes to remove residual moisture from the surface of the metal corner protectors and improve the adhesion of the dip coating.

[0035] To further optimize this technical solution, the size and position of the groove in the metal corner protector are designed according to the shape of the product, and the amount of cushioning material used is determined by filling the groove according to its size.

[0036] Compared with the prior art, the present invention provides a metal corner protector processing technology with elastic buffering and anti-collision functions, which has the following beneficial effects:

[0037] 1. This metal corner protector processing technology with elastic cushioning and anti-collision functions uses 65Mn material to make the metal corner protector, and uses heat treatment processes such as quenching to make the metal corner protector highly elastic, so that the metal corner protector can buffer external forces on the product; then, by dip-coating the metal corner protector, the surface hardness of the metal corner protector becomes soft, and burrs are also covered. The dip-coating has a relatively thick and tough coating, with strong impact resistance and wear resistance, and can be used in direct contact with products and packaging.

[0038] 2. This metal corner protector processing technology with elastic cushioning and anti-collision functions, by setting cushioning material, places a cushioning material with good cushioning performance inside the metal corner protector, making the metal corner protector more impact resistant and better protecting the product. Attached Figure Description

[0039] Figure 1 This is a schematic diagram of the processing technology for a metal corner protector with elastic buffering and anti-collision functions proposed in this invention;

[0040] Figure 2 This is a schematic diagram of the structure of a metal corner protector with elastic buffering and anti-collision functions proposed in this invention when it is not filled.

[0041] Figure 3 This is a schematic diagram of the structure of a metal corner protector with elastic cushioning and anti-collision functions after being filled with cushioning material, as proposed in this invention.

[0042] Figure 4 These are schematic diagrams of the structure of metal corner protectors without filling in various embodiments;

[0043] Figure 5 This is a schematic diagram of the structure of metal corner protectors with various filling and cushioning materials in different embodiments.

[0044] In the picture: 1. Corner protector body; 2. Groove; 3. Buffer material. Detailed Implementation

[0045] To provide a more detailed understanding of the features and technical content of the embodiments of this disclosure, the implementation of the embodiments of this disclosure will be described in detail below with reference to the accompanying drawings. The accompanying drawings are for illustrative purposes only and are not intended to limit the embodiments of this disclosure. In the following technical description, for ease of explanation, several details are used to provide a full understanding of the disclosed embodiments. However, one or more embodiments may still be implemented without these details. In other cases, well-known structures and devices may be simplified in their depiction to simplify the drawings.

[0046] The terms "first," "second," etc., used in the specification, claims, and accompanying drawings of this disclosure are used to distinguish similar objects and are not necessarily used to describe a specific order or sequence. It should be understood that such data can be interchanged where appropriate for the embodiments of this disclosure described herein. Furthermore, the terms "comprising" and "having," and any variations thereof, are intended to cover non-exclusive inclusion.

[0047] In the embodiments of this disclosure, the terms "upper," "lower," "inner," "middle," "outer," "front," and "rear," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. These terms are primarily for better describing the embodiments of this disclosure and are not intended to limit the indicated device, element, or component to having a specific orientation, or to be constructed and operated in a specific orientation. Furthermore, some of the aforementioned terms may be used to indicate other meanings besides orientation or positional relationship; for example, the term "upper" may in some cases indicate a dependency or connection relationship. Those skilled in the art can understand the specific meaning of these terms in the embodiments of this disclosure according to the specific circumstances.

[0048] Furthermore, the terms "set up," "connect," and "fix" should be interpreted broadly. For example, "connection" can be a fixed connection, a detachable connection, or an integral structure; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium, or it can be an internal connection between two devices, components, or parts. Those skilled in the art can understand the specific meaning of the above terms in the embodiments of this disclosure according to the specific circumstances.

[0049] Unless otherwise stated, the term "multiple" means two or more.

[0050] It should be noted that, unless otherwise specified, the embodiments and features described in the present disclosure can be combined with each other.

[0051] Example 1:

[0052] Please see Figure 1 A metal corner protector manufacturing process with elastic cushioning and impact protection functions includes the following steps:

[0053] S1. Metal corner protectors made of 65Mn sheet metal material.

[0054] The metal corner protectors are made with a convex-cavity structure featuring a groove. This convex-cavity structure provides excellent elasticity to cushion external impacts during drops.

[0055] Furthermore, such as Figure 2 and Figure 3 As shown, the metal corner protector includes a corner protector body 1, which has a convex-cavity structure. A groove 2 is formed on the inner surface of the corner protector body 1, and the cushioning material 3 fills the inside of the groove 2. The position and size of the groove 2 of the metal corner protector are designed according to the shape of the product, and the amount of cushioning material 3 used is determined according to the size of the groove 2.

[0056] Furthermore, the cushioning material 3 is a material with good cushioning properties, including pearl cotton, EVA, rubber and silicone foam, and the cushioning material 3 is placed inside the groove 2 by means of bonding, embedding or polymerization.

[0057] S2. The finished metal corner protectors are then quenched.

[0058] The quenching process includes:

[0059] The metal corner protector is heated to 850°C to allow the metal grains to grow and change its crystal structure. It is kept at 850°C for 1-2 hours to ensure that the metal corner protector is heated evenly.

[0060] After heating, the metal corner protectors are quickly cooled to room temperature to form a martensitic structure, which is used to increase the hardness of the metal corner protectors.

[0061] Clean the oxides or other contaminants generated on the surface of the quenched metal corner protectors to ensure that the surface of the metal corner protectors is clean.

[0062] S3. Temper the metal corner protectors to achieve a hardness of HRC48.

[0063] The tempering process includes:

[0064] Heat the quenched metal corner protectors to a temperature range of 200-300℃ and maintain this temperature for 2-3 hours. The tempering time should ensure that the metal corner protectors are fully tempered.

[0065] After tempering is completed, allow the metal corner protectors to cool naturally or control the cooling rate to achieve the preset elasticity and hardness.

[0066] A hardness test was conducted using a Rockwell hardness test to ensure that the metal corner protectors reached the target hardness value of HRC48.

[0067] Furthermore, the preset elasticity of the metal corner protector is described by the elastic modulus, which is the ability of a material to undergo elastic deformation under stress. The relationship between the elastic modulus (E) and stress (σ) and strain (ε) is expressed by the following formula:

[0068] [\sigma=E\cdot\varepsilon]

[0069] Where (σ) is stress, measured in Pascals (Pa) or Megapascals (MPa); (E) is the elastic modulus, measured in Pascals (Pa) or Megapascals (MPa); (σ) is stress; and (varepsilon) is strain, which is the deformation per unit length of the material.

[0070] S4. After tempering, the metal corner protectors are coated with plastic to form a 1-2 mm plastic coating on the surface of the metal corner protectors.

[0071] The dip coating process includes:

[0072] Use solvent cleaning, alkaline cleaning, or sandblasting to perform a secondary cleaning on the surface of the metal corner protectors;

[0073] Pre-treatment is performed on the cleaned metal corner protectors;

[0074] Furthermore, the preprocessing includes:

[0075] The surface of the metal corner protector is sanded to increase its roughness.

[0076] The metal corner protectors are placed in an oven and heated at 100-120℃ for 1-2 minutes to remove residual moisture from the surface of the metal corner protectors and improve the adhesion of the dip coating.

[0077] Choose PVC or nylon granules or powder as the dip coating material;

[0078] The dip-coating material is heated to its melting temperature to form a molten coating material.

[0079] The pre-treated metal corner protectors are immersed in molten PVC or nylon material. The thickness and uniformity of the dip coating are adjusted by controlling the immersion time and lifting speed to ensure that the entire surface is uniformly coated.

[0080] The coated metal corner protectors are placed in a cooling tank for rapid cooling and curing to form a strong dip-coated layer.

[0081] This process transforms the hard metal corner protector into a softer plastic surface, while also covering the burrs at the metal breakage point. This prevents the product from being scratched or punctured when used for product packaging protection. The PVC or nylon material used for the dip coating also has excellent impact resistance and other mechanical properties, ensuring the strength of the dip coating layer.

[0082] S5. Fill the metal corner protector with cushioning material 3. By setting the cushioning material 3, the cushioning material 3 with good cushioning performance is placed inside the metal corner protector, making the metal corner protector more impact resistant and better protecting the product.

[0083] Example 2:

[0084] Please see Figure 4 and Figure 5 Based on the metal corner protector with elastic buffering and anti-collision functions described in Embodiment 1, the corner protector body 1 in the metal corner protector can be designed as follows: Figure 4Any shape is allowed, and the location and shape of the groove 2 are adapted to the product being protected, and as shown in the example. Figure 5 As shown, an appropriate amount of cushioning material 3 is filled inside the groove 2.

[0085] The beneficial effects of this invention are:

[0086] 1. This metal corner protector processing technology with elastic cushioning and anti-collision functions uses 65Mn material to make the metal corner protector, and uses heat treatment processes such as quenching to make the metal corner protector highly elastic, so that the metal corner protector can buffer external forces on the product; then, by dip-coating the metal corner protector, the surface hardness of the metal corner protector becomes soft, and burrs are also covered. The dip-coating has a relatively thick and tough coating, with strong impact resistance and wear resistance, and can be used in direct contact with products and packaging.

[0087] 2. This metal corner protector processing technology with elastic cushioning and anti-collision functions, by setting cushioning material, places a cushioning material with good cushioning performance inside the metal corner protector, making the metal corner protector more impact resistant and better protecting the product.

[0088] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A processing technology for metal corner protectors with elastic cushioning and anti-collision functions, characterized in that, Includes the following steps: S1. Metal corner protectors made from 65Mn sheet metal material; S2. Quench the finished metal corner protectors; S3. Temper the metal corner protectors to achieve a hardness of HRC48. S4. After tempering, the metal corner protectors are coated with plastic to form a 1-2 mm plastic coating on the surface of the metal corner protectors. S5. Fill the metal corner protectors with cushioning material; In step S4, the dip coating process includes: Use solvent cleaning, alkaline cleaning, or sandblasting to perform a secondary cleaning on the surface of the metal corner protectors; Pre-treatment is performed on the cleaned metal corner protectors; Choose PVC or nylon granules or powder as the dip coating material; The dip-coating material is heated to its melting temperature to form a molten coating material; The pre-treated metal corner protectors are immersed in molten PVC or nylon material. The thickness and uniformity of the dip coating are adjusted by controlling the immersion time and lifting speed to ensure that the entire surface is uniformly coated. The coated metal corner protectors are placed in a cooling tank for rapid cooling and curing to form a robust dip-coated layer; the pretreatment includes: The surface of the metal corner protector is sanded to increase its roughness. The metal corner protectors are placed in an oven and heated at 100-120℃ for 1-2 minutes to remove residual moisture from the surface of the metal corner protectors and improve the adhesion of the dip coating.

2. The metal corner protector processing technology with elastic buffering and anti-collision functions according to claim 1, characterized in that, In step S1, the metal corner protector is made into a metal corner protector with a convex cavity structure with a groove shape.

3. The metal corner protector processing technology with elastic buffering and anti-collision functions according to claim 2, characterized in that, The metal corner protector includes a corner protector body, which has a convex cavity structure. A groove is formed on the inner surface of the corner protector body, and the cushioning material is filled inside the groove.

4. The metal corner protector processing technology with elastic buffering and anti-collision functions according to claim 3, characterized in that, The cushioning material is a material with good cushioning properties, including pearl cotton, EVA, rubber and silicone foam. The cushioning material is placed inside the groove by means of bonding, embedding or polymerization.

5. The metal corner protector processing technology with elastic buffering and anti-collision functions according to claim 1, characterized in that, In step S2, the quenching process includes: The metal corner protector is heated to 850°C to allow the metal grains to grow and change its crystal structure. It is kept at 850°C for 1-2 hours to ensure that the metal corner protector is heated evenly. After heating, the metal corner protectors are quickly cooled to room temperature to form a martensitic structure, which is used to increase the hardness of the metal corner protectors. Clean the oxides or other contaminants generated on the surface of the quenched metal corner protectors to ensure that the surface of the metal corner protectors is clean.

6. The metal corner protector processing technology with elastic buffering and anti-collision functions according to claim 1, characterized in that, In step S3, the tempering process includes: Heat the quenched metal corner protectors to a temperature range of 200-300℃ and maintain this temperature for 2-3 hours. The tempering time should ensure that the metal corner protectors are fully tempered. After tempering is completed, allow the metal corner protectors to cool naturally or control the cooling rate to achieve the preset elasticity and hardness. A hardness test was conducted using a Rockwell hardness test to ensure that the metal corner protectors reached the target hardness value of HRC48.

7. The metal corner protector processing technology with elastic buffering and anti-collision functions according to claim 3, characterized in that, The size and position of the groove in the metal corner protector are designed according to the shape of the product, and the amount of cushioning material used is determined by the size of the groove.

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