Phosphated Screw Silicate Sealing and Rolling Process
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Solution Overview
Problem
Phosphated screws in the automotive industry require oiling for corrosion resistance and friction coefficient compliance, leading to oil residue issues in transport packaging and system contamination, resulting in unnecessary downtime and potential faulty connections.
Innovation Solution
Applying a silicate seal after phosphating, followed by rolling the screws, which presses phosphate flakes into the thread flanks to enhance friction behavior and corrosion protection, using products like Delta-Protekt® VH301 GZ or Plus® VL PLS0218, creating a pressure-stable, abrasion-resistant dry lubricating film.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If screws are oiled after phosphating to achieve required corrosion resistance and friction coefficient, then corrosion protection and friction properties are improved, but oil residue accumulates in transport packaging and contaminates automated assembly systems
Solution Approach 1:
The invention changes the physical-chemical state of the protective coating by using a silicate-based sealing agent that transforms the phosphated surface into a dry film structure. This parameter change eliminates the need for liquid oil while maintaining corrosion protection and friction properties through the silicate gel network formation and phosphate flake orientation during rolling
Solution Approach 2:
The invention extracts and removes the harmful liquid oil component from the system while retaining the essential protective functions. The silicate sealing process replaces the oil layer with a dry film that provides the same corrosion resistance and friction control without the unwanted oil residue that contaminates packaging and assembly systems
2Ease of operation
If anti-friction coatings are applied to phosphated screws to reduce friction, then friction coefficient is improved, but the coating layer becomes too thick or causes excessive abrasion
Solution Approach 1:
The invention changes the fundamental mechanism of friction reduction from a thick external coating to a thin integrated surface modification. The silicate sealing process creates a gel network within the phosphate layer structure, and the subsequent rolling process orients phosphate flakes to provide low friction through solid lubrication mechanisms rather than relying on a thick organic coating layer
Solution Approach 2:
The invention creates a composite structure where silicate sealant integrates with the phosphate layer to form a unified coating system. The silicate gel network combines with oriented phosphate flakes to produce a composite surface layer that provides both friction reduction and mechanical strength without the thickness and abrasion problems of conventional anti-friction coatings
3Ease of operation
If screws are rolled after phosphating to orient phosphate flakes for friction control, then friction behavior is improved, but corrosion protection may be compromised without additional sealing
Solution Approach 1:
The invention applies the silicate sealing treatment before the rolling process to prepare the phosphate surface for optimal flake orientation. The silicate gel network forms first, creating a stable matrix that allows phosphate flakes to be subsequently oriented during rolling while maintaining corrosion protection through the sealed structure
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
This method achieves a favorable friction behavior and increased corrosion protection with a thin, durable lubricating film, eliminating the need for oil and reducing system contamination.
Implementation Method 1
a pressure-stable, abrasion-resistant dry 'lubricating film' with only a very small layer thickness is obtained
Implementation Method 2
the phosphated screw is provided with a silicate seal after the phosphating
Implementation Method 3
phosphate flakes are pressed into the flanks of the thread and influence the friction behavior there
Data Source
AI summary
Phosphated screw which after phosphating is provided with a siliceous sealing layer and has been rolled only after phosphating and after application of the siliceous sealing layer.