Biodegradable Grease for Galvanized Steel Cables
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Solution Overview
Problem
Current lubricants for steel cables, particularly galvanized steel cables, fail to meet the requirements of being environmentally friendly, effective in a wide temperature range, and suitable for use in water environments while maintaining the integrity of the zinc layer, and adhering to environmentally acceptable lubricant standards.
Innovation Solution
A lubricating grease composed of biodegradable base oils and esters, calcium soaps, and specific additives that provide excellent lubrication, corrosion protection, and adhesion without harming the zinc layer, meeting the criteria for environmentally acceptable lubricants and maintaining performance in varying temperatures and water exposure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional lubricants are used for steel cables, then lubrication performance is achieved, but environmental friendliness and compatibility with zinc coating are compromised
Solution Approach 1:
The patent changes the chemical composition parameters of the lubricant by specifying precise ranges for base oil (50-90 wt%), calcium soap (3-12 wt%), and additives (1-20 wt%). This parameter optimization ensures the lubricant achieves reliable lubrication while being biodegradable and non-toxic, resolving the contradiction between performance and environmental compatibility.
Solution Approach 2:
The patent creates a composite lubricant system combining base oil, calcium soap thickener, and specific additives (pyrogenic silicon dioxide, polytetrafluoroethylene, polymers). This composite formulation provides both excellent lubrication performance and environmental friendliness, as each component contributes specific properties that together satisfy both performance and EAL requirements.
2Temperature
If lubricants are formulated for wide temperature range performance, then thermal stability is improved, but biodegradability and environmental acceptability may be compromised
Solution Approach 1:
The patent specifies precise parameter ranges for base oil viscosity (18-1200 mm²/s at 40°C), calcium soap content (3-12 wt%), and additive concentrations. These parameter optimizations enable the lubricant to maintain performance across wide temperature ranges while ensuring biodegradability and non-toxicity, resolving the contradiction between thermal stability and environmental acceptability.
3Object-affected harmful factors
If lubricants are designed to be biodegradable and non-toxic, then environmental acceptability is improved, but lubrication effectiveness and adhesion may be reduced
Solution Approach 1:
The patent develops a composite lubricant system where biodegradable base oil is combined with calcium soap thickener and specific additives including pyrogenic silicon dioxide, polytetrafluoroethylene, and polymers. This composite formulation maintains biodegradability and non-toxicity while ensuring excellent lubrication effectiveness and adhesion to steel cables, resolving the contradiction between environmental friendliness and performance.
4Reliability
If lubricants are used on galvanized steel cables, then corrosion protection is achieved, but compatibility with zinc layer must be maintained
Solution Approach 1:
The patent optimizes the chemical composition parameters, specifically requiring base oil with controlled viscosity and pH, calcium soap content (3-12 wt%), and specific additive ranges. These parameter controls ensure the lubricant provides corrosion protection while being chemically compatible with the zinc coating, preventing damage to the galvanization layer.
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 lubricating grease demonstrates outstanding lubricating properties, maintains the zinc layer's integrity, and meets the criteria for environmentally acceptable lubricants, ensuring effective performance in marine and oil and gas industry applications.
Implementation Method 1
Lubricants for steel cables are used to separate the individual strands of the cable with a lubricating film, thus reducing wear
Implementation Method 2
protecting the steel cable as a whole against corrosion
Data Source
AI summary
The invention relates to an environmentally friendly lubricating grease for steel ropes, in particular zinc-plated steel ropes, comprising: 50 wt.% to 90 wt.% of a biodegradable base stock, in particular of a biodegradable ester as the base stock, b) 3 wt.% to 25 wt.% and/or 7 wt.% to 20 wt.% of a thickening agent selected from b1) 3 wt.% to 12 wt.% biodegradable calcium soap, b2) 3 wt.% to 25 wt.% and/or 3.5 wt.% to 20 wt.% and/or 4 wt.% to 12 wt.% bentonite, b3) and mixtures thereof, c) 4 wt.% to 40 wt.%, preferably 7 wt.% to 40 wt.% additives, comprising c1) 1 wt.% to 12 wt.% and/or 4 wt.% to 12 wt.% pyrogenic silicon dioxide and/or polytetrafluoroethylene and mixtures thereof, c2) 2 wt.% to 45 wt.% and/or 2 wt.% to 25 wt.% of a polymer selected from polyisobutylene, polyisobutylene-/butene copolymer, polymethacrylates, polyesters, preferably complex esters, in particular complex esters of neopentylglycol/dimeric acid/2-ethylhexanol and mixtures thereof, and c3) 0.5 wt.% to 20 wt.% and/or 1 wt.% to 10 wt.% of a solid lubricant.