Aqueous Release Agent for Metal Forming
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Solution Overview
Problem
Existing aqueous compositions used in metal forming methods, such as those containing silicone oil, face issues with accumulation in molds, insufficient heat resistance, and odor, leading to contamination and defects in molded products.
Innovation Solution
An aqueous composition comprising carboxylic acid compounds, carboxylic anhydrides, trimellitic anhydride, and a basic compound, which enhances releasability, lubricity, adhesion, and heat resistance while minimizing odorousness, is developed for use as a release agent and lubricant in metal forming processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If silicone oil is used as a main component in aqueous composition, then releasability and lubricity are improved, but heat resistance is insufficient and odor is generated
Solution Approach 1:
The patent changes the chemical composition parameters by replacing silicone oil with fluorinated compounds (specifically fluorinated esters and fluorinated ethers) that have higher thermal stability. This parameter change maintains the releasability function while improving heat resistance, as fluorinated compounds can withstand higher temperatures without degradation or odor generation.
Solution Approach 2:
The patent uses composite fluorinated compounds comprising multiple components (fluorinated esters and fluorinated ethers in specific ratios) to achieve both excellent releasability and heat resistance. The composite structure allows synergistic effects where the combination of fluorinated compounds provides superior thermal stability compared to single-component silicone oil systems.
2Reliability
If silicone oil is used as a main component in aqueous composition, then releasability and lubricity are improved, but contamination of mold occurs
Solution Approach 1:
The patent changes the chemical nature of the release agent from silicone oil to fluorinated compounds, which have different surface properties and thermal stability. This parameter change prevents contamination by ensuring the release agent remains stable at molding temperatures and does not decompose or transfer unwanted residues to the mold or product.
Solution Approach 2:
The fluorinated compounds used in the patent are designed to be stable and non-contaminating, effectively replacing the need for frequent mold cleaning that would be required with silicone oil systems. The composition acts as a disposable release layer that does not accumulate harmful residues.
3Productivity
If high concentration aqueous release agent is used, then drying efficiency is improved and waste liquid is reduced, but odor is generated
Solution Approach 1:
The patent changes the chemical composition from silicone oil-based to fluorinated compound-based, which fundamentally alters the odor profile. The fluorinated compounds have inherently lower odorousness even at high concentrations, allowing the formulation to achieve high drying efficiency without generating unpleasant odors during application and evaporation.
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 composition provides improved releasability, lubricity, and heat resistance, reduces odor, and prevents contamination, resulting in higher-quality molded products and extended mold life.
Implementation Method 1
an aqueous composition comprises at least one selected from a group consisting of a carboxylic acid compound represented by the following formula (1), a carboxylic anhydride represented by the following formula (2), and a trimellitic anhydride; a basic compound; and water
Data Source
AI summary
According to an aspect of the present invention, an aqueous composition contains at least one selected from a group consisting of a carboxylic acid compound represented by the following formula (1), a carboxylic anhydride represented by the following formula (2), and a trimellitic anhydride; a basic compound; and water. In the formula (1), “R” represents an alkanediyl group having 2 to 4 carbons, a vinylene group, or a benzene ring, and “a” represents 2 or 3. In the formula (2), “R” represents an alkanediyl group having 2 to 4 carbons, a vinylene group, or a benzene ring.