High-PREN Metal Models for Durable NBR Latex Production
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Solution Overview
Problem
Existing ceramic models for NBR latex production suffer from low production qualification rates, high shrinkage, uneven surfaces, short service life, poor thermal shock resistance, poor dimensional accuracy, excessive heat energy loss, and high weight, among other issues.
Innovation Solution
A metal material comprising specific alloy compositions (e.g., SUS304, SUS316L) is used to create a metal model with pitted surfaces and anti-corrosion layers, prepared through processes like laser welding, pitting, and electroplating to enhance durability and thermal conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If ceramic models are used for NBR latex production, then the model provides acid and alkali resistance, but the production qualification rate is low (85%) and service life is short (3-8 months)
Solution Approach 1:
The patent changes the material parameter from ceramic to metal (specifically aluminum alloy with 6061 or 6063 composition), which fundamentally alters the performance characteristics. The metal model achieves both high service life (over 1 year) and high production qualification rate (95% or above) by leveraging the inherent properties of metal materials including better thermal conductivity, chemical resistance, and mechanical strength compared to ceramic materials.
2Manufacturing precision
If ceramic models are used, then the model structure is simple, but the dimensional accuracy is poor and wall thickness is too thick (4-8 mm)
Solution Approach 1:
The patent optimizes the wall thickness parameter from the ceramic standard (4-8 mm) to a metal-appropriate thickness (2-4 mm), achieving better dimensional accuracy while reducing material usage. The aluminum alloy material's superior casting precision and dimensional stability enable tighter tolerances and smoother surfaces compared to ceramic models.
3Loss of energy
If ceramic models are used, then the model is heavy, but thermal conductivity is poor resulting in excessive heat energy loss
Solution Approach 1:
The patent changes the material from ceramic to aluminum alloy, which has superior thermal conductivity (approximately 3 times higher than ceramic). This reduces heat energy loss during the NBR latex production process while the lightweight nature of aluminum (comparing to ceramic density) actually reduces the model weight, creating a dual benefit.
4Reliability
If ceramic models are used, then the model provides corrosion resistance, but thermal shock resistance is not strong
Solution Approach 1:
The patent transitions from ceramic to aluminum alloy material, which inherently provides superior thermal shock resistance due to higher thermal conductivity and lower thermal expansion coefficient. The aluminum alloy also maintains excellent corrosion resistance through its natural oxide layer formation, achieving both thermal shock resistance and corrosion resistance simultaneously.
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 metal models exhibit improved acid and alkali resistance, longer service life, better thermal shock resistance, reduced weight, and lower energy consumption, producing NBR latex products with enhanced wear resistance and uniformity.
Implementation Method 1
connecting the models of the palm, the arm and the base to realize preparation of the metal model
Implementation Method 2
carrying out surface treatment on the integral model with the pitted surface to form an anti-corrosion and wear-resistant layer
Data Source
AI summary
The present invention provides a metal material and use thereof in preparing a metal model. The metal material comprises the following ingredients in percentage by weight: C≤0.06%, Si≤1.00%, 1.00%≤Mn≤4.00%, P≤0.045%, S≤0.005%, 20.00%≤Cr≤22.00%, 8.50%≤Ni≤10.50%, 1.00%≤Mos2.50%, 1.00%≤Cu≤3.50%, 0.20%≤N≤0.30%, with the balance being Fe; the pitting resistance equivalent number (PREN) of the metal material is calculated according to the formula: PREN=Cr %+3.3M0%+16N %, and the result is PREN≥30.0%