Paste Brazing Filler Powder Mix for Stable Viscosity
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Solution Overview
Problem
The production of water-soluble binder-based paste brazing filler metals is hindered by the formation of mamako (lumps) due to prolonged agitation and viscosity instability, requiring a lengthy dispersion period, which slows down the manufacturing process and affects the quality of the paste.
Innovation Solution
A mixed powder comprising brazing filler metal and a water-soluble thickening agent, such as cellulose-based resins, is used to suppress mamako formation, eliminating the need for a separate binder manufacturing process, with specific ratios and additives to achieve stable viscosity and prevent precipitation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If water-soluble binder is used to reduce environmental impact and eliminate explosion-proof facilities, then environmental safety is improved, but mamako formation occurs requiring prolonged agitation and dispersion period
Solution Approach 1:
The patent changes the physical state of the thickening agent from liquid to powder form. This parameter change prevents mamako formation during mixing while maintaining the water-soluble binder's environmental safety benefits. The powder form allows uniform distribution without gel layer formation that characterizes liquid binder mixing.
Solution Approach 2:
The patent uses resin powder that replicates the thickening function of liquid water-soluble binders without the associated mixing problems. The powder form copies the functional properties (water solubility, thickening effect) while eliminating the harmful side effect of mamako formation, thus reducing dispersion time.
2Device complexity
If water-soluble binder is used to eliminate explosion-proof facilities, then device complexity is reduced, but viscosity stability becomes unstable due to mamako generation and water volatilization
Solution Approach 1:
Changing the thickening agent from liquid to powder form stabilizes viscosity by preventing mamako formation. The powder form ensures uniform water absorption and distribution, eliminating the viscosity fluctuations caused by gel layer formation and water volatilization that occur with liquid binders.
Solution Approach 2:
The resin powder acts as a single-use, pre-prepared thickening agent that is mixed directly with the brazing filler metal powder. This eliminates the need for separate binder preparation and ensures consistent viscosity without the stability issues of liquid binders that are susceptible to water volatilization and mamako formation.
3Ease of manufacture
If liquid water-soluble thickening agent is used, then ease of manufacture is improved, but production time increases due to prolonged agitation and dispersion period
Solution Approach 1:
The patent changes the physical state of the thickening agent from liquid to powder, which maintains ease of manufacture through simple mixing while dramatically reducing the dispersion period. The powder form requires no special agitation equipment or prolonged mixing times, thus improving productivity while keeping the manufacturing process simple.
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 method results in a paste brazing filler metal with stable viscosity and no precipitation, enhancing application workability and reducing production time, thus simplifying the manufacturing process and improving the quality of the final product.
Implementation Method 1
lumps called mamako (lumps where only the outer surface of the powder particles or their aggregates are hydrated to form a viscous gel layer which inhibits water penetration into the interior)
Implementation Method 2
the water-soluble resin that serves as the thickening agent is dissolved in aqueous solution
Data Source
AI summary
Provided is a mixed powder for a paste brazing filler metal; a paste brazing filler metal produced using the mixed powder; and a method for producing the paste brazing filler metal. A paste brazing filler metal according to the present invention can be produced by mixing 8.0 to 22.0 parts by mass of an aqueous solution containing an organic solvent, etc. with 100 parts by mass of a mixed powder for a paste brazing filler metal, wherein the mass ratio of a brazing filler metal powder to a resin powder of water-soluble thickening agent is 99.88 to 97.90: 0.12 to 2.10. It is preferable that the resin powder is cellulose-based. And it is particularly preferable that the resin powder is one or two selected from methyl cellulose, carboxymethyl cellulose, hydroxyethyl cellulose, hydroxypropyl cellulose and hydroxypropylmethyl cellulose.