Cold-Washable Metal Strip Lubricant Composition
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Solution Overview
Problem
Current lubricant compositions for metal strips require high temperatures for removal, which is energy-intensive and costly, and they lack compatibility with various metal processing stages, leading to inefficiencies and residue issues.
Innovation Solution
A cold-washable lubricant composition comprising a mixture of base oils with varying kinematic viscosities, sulfonate-based corrosion inhibitors, ester components, phosphorus carriers, and emulsifiers, allowing for effective corrosion protection, lubrication, and easy removal at room temperature.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional lubricant compositions are used for corrosion protection and lubrication, then effective protection and lubrication are achieved, but high temperatures are required for removal which increases energy consumption and costs
Solution Approach 1:
The invention changes the chemical composition parameters of the lubricant by incorporating specific emulsifiers and surfactants that enable cold washability. The lubricant contains water-soluble emulsifiers and surfactants that allow the oil-based lubricant to be emulsified and removed at room temperature, fundamentally altering the removal temperature parameter from high temperature to ambient temperature.
Solution Approach 2:
The invention creates a composite lubricant system that combines water-soluble emulsifiers, surfactants, and oil-based lubricating components. This composite formulation allows the lubricant to maintain oil-like protective properties while gaining water-solubility for easy removal, effectively combining the benefits of both water-based and oil-based lubricants.
2Reliability
If conventional lubricant compositions are used, then lubrication and corrosion protection are provided, but they lack compatibility with various metal processing stages leading to residue issues
Solution Approach 1:
The invention creates a universal lubricant composition that performs multiple functions across different metal processing stages. The lubricant provides corrosion protection during storage, lubrication during forming operations, and easy removal during cleaning, all with a single formulation. The emulsifier and surfactant system enables the lubricant to be compatible with subsequent painting and coating processes without causing residue issues.
3Reliability
If high-viscosity base oils are used for lubrication, then lubricating effect is improved, but removal becomes more difficult and energy-intensive
Solution Approach 1:
The invention introduces emulsifiers and surfactants as intermediary substances that facilitate the removal of high-viscosity lubricant. These intermediaries act as bridges between the oil-based lubricant and water-based cleaning systems, allowing the viscous lubricant to be emulsified and easily removed without requiring high temperatures or excessive energy input.
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 enables efficient cold washing, reduces energy consumption, and ensures compatibility with all metal processing stages, preventing residue and improving production efficiency.
Implementation Method 1
The lubricant composition can be washed off cold, so that facilities as well as energy and costs for heating cleaning baths in the pretreatment of formed sheet metal parts can be saved
Implementation Method 2
which are selected from base oils of Group I and Group II with a kinematic viscosity at 40 ° C of 3 to 700 mm 2/s and a mixture ratio by weight of the first base oil to the second base oil of 95:5 to 50:50
Implementation Method 3
5 to 15% by weight of sulfonate-based corrosion inhibitor
Implementation Method 4
10 to 30% by weight of ester component, which consists of saturated fatty acid esters
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The present invention provides a lubricant composition which can be washed off cold and the use thereof for application to a metal strip as anti-corrosion, wash and/or forming lubricant. The composition is 50 to 90 wt% base fluid, 3 to 15 wt% sulfonate-based corrosion inhibitor, 1 to 20 wt% ester component, 0.5 to 3 wt% phosphorus source component or 1 to 10 wt% sulfur source component as high-pressure/anti-wear additive, 1 to 15 wt% emulsifier, 0.05 to 1 wt% carboxylic acid component, 0.05 to 1 wt% aminic and/or phenolic antioxidant, 0.5 to 5 wt% wax and/or thickener component, based in each case on the total weight of the composition. Further disclosed is a dry lubricant composition which can be washed off cold.