Halogenated Hydrocarbon Cleaning Solvent with Phosphate Ester Surfactants
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Solution Overview
Problem
Current solvent-based cleaning compositions face challenges in effectively removing specific soiling substances, such as flux residues and solder pastes, from metal surfaces, often leaving behind residues or requiring multiple rinses, especially in non-aqueous cleaners.
Innovation Solution
The composition combines free acid forms of phosphate ester surfactants with halogenated hydrocarbon solvents and alcohols, optimizing mutual solvency and cleaning efficiency, with specific weight percentages of each component to enhance the removal of tough residues.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If non-aqueous cleaners are used to clean metal surfaces, then flammability safety is improved, but cleaning effectiveness deteriorates
Solution Approach 1:
The patent combines multiple solvent types (halogenated hydrocarbons, alcohols, esters) with phosphate ester surfactants to create a non-aqueous cleaning composition that achieves both safety and effectiveness. The synergistic combination allows the mixture to remove difficult soils like flux residues and solder pastes while maintaining non-flammable properties through the halogenated hydrocarbon base.
Solution Approach 2:
The cleaning composition uses a composite formulation with specific weight ratios of different chemical components: halogenated hydrocarbons (50-95%), alcohols (5-30%), esters (5-20%), and phosphate ester surfactants (0.1-5%). This composite approach creates a non-aqueous solvent system that overcomes the limitations of individual components.
2Ease of operation
If conventional solvent-based cleaning compositions are used, then ease of operation is improved, but manufacturing precision deteriorates
Solution Approach 1:
The patent optimizes the concentration parameters of each component to achieve superior cleaning results. Specifically, phosphate ester surfactants are used at 0.1-5% concentration, halogenated hydrocarbons at 50-95%, alcohols at 5-30%, and esters at 5-20%. These parameter optimizations enable complete removal of residues that conventional formulations leave behind.
Solution Approach 2:
Phosphate ester surfactants act as intermediary substances that enhance the cleaning action of the non-aqueous solvents. These surfactants mediate between the solvent system and the difficult-to-remove soils (flux residues, solder pastes), enabling effective removal while maintaining the non-aqueous nature of the formulation.
3Manufacturing precision
If multiple rinses are used to remove residues, then manufacturing precision is improved, but loss of time increases
Solution Approach 1:
The cleaning composition is formulated with phosphate ester surfactants and optimized solvent ratios to perform the cleaning action completely in a single application. This preliminary action ensures that all residues are removed during the initial cleaning step, eliminating the need for subsequent rinsing operations and reducing total process time.
Solution Approach 2:
The non-aqueous cleaning composition is designed to be self-rinsing, where the solvent mixture itself carries away all residues without requiring additional water rinsing steps. The formulation achieves complete cleaning in one step, making the system self-sufficient and eliminating time-consuming multiple rinse cycles.
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 combination of phosphate ester surfactants, halogenated hydrocarbons, and alcohols in the cleaning solvent compositions significantly improves the removal of residues, achieving cleaner surfaces and metal brightening with fewer rinses, as demonstrated in various trials.
Implementation Method 1
A widely used class of additives is phosphate esters, known for use as anionic surfactants
Implementation Method 2
one or more free acid forms of phosphate ester surfactants selected from the group consisting of
Implementation Method 3
from about 25 to about 97.8 weight percent of one or more halogenated hydrocarbon solvents
Implementation Method 4
from about 2 to about 25 weight percent of an alcohol selected from the group consisting of one or more of straight chain and branched alkyl alcohols
Data Source
AI summary
A cleaning solvent composition comprises from about 0.2 to 15 weight percent of mono- or di-phosphate ester in free acid form, and from about 85 to 99.8 weight percent of one or more halogenated hydrocarbon solvents. Other cleaning solvent compositions further comprise one or more alcohols. For example, such alcohol-containing compositions may comprise from about 0.2 to 15 weight percent of mono- or di-phosphate ester in free acid form, from about 2 to about 25 weight percent of one or more alcohols, and from about 25 to about 97.8 weight percent of one or more halogenated hydrocarbon solvents.