Phosphated Wire Anti-Corrosion Emulsion Prevents Oil Drips
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Solution Overview
Problem
The handling of metal workpieces coated with oil-based corrosion protection agents is problematic due to oil dripping, causing pollution and making handling unpleasant, and existing corrosion protection methods do not adequately prevent corrosion during storage and mechanical stress.
Innovation Solution
A corrosion protection agent with a composition of 5-75% oil and 25-95% surfactant, specifically designed to fully occupy the metal surface without excess oil, ensuring effective corrosion protection without oil runoff, and containing no heavy metals or harmful substances, suitable for steel wire processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If oil-based corrosion protection agent is applied to metal surface, then corrosion protection is improved, but oil dripping occurs causing pollution and handling difficulties
Solution Approach 1:
The patent changes the physical-chemical parameters of the corrosion protection agent by using a water-based emulsion with controlled oil content (5-75 wt%) and surfactant content (25-95 wt%), replacing conventional pure oil-based agents. This parameter change allows the coating to provide corrosion protection while preventing oil dripping and improving handling characteristics.
Solution Approach 2:
The patent creates a composite corrosion protection agent consisting of water, oil, surfactant, and optionally wax or polymer additives. This composite formulation combines the corrosion protection benefits of oil with the handling advantages of water-based systems, eliminating the drawbacks of pure oil-based agents.
2Reliability
If conventional oil-based corrosion inhibitor is applied, then corrosion protection is achieved, but excess oil runs off the surface causing contamination
Solution Approach 1:
The patent introduces surfactants as intermediary substances that mediate between the oil and water phases, enabling the oil to be dispersed uniformly throughout the water-based system. The surfactant acts as a bridge that prevents oil coalescence and runoff while maintaining corrosion protection.
Solution Approach 2:
By controlling the oil content parameter within 5-75 wt% and surfactant content within 25-95 wt%, the patent creates a formulation where oil is sufficiently dispersed to provide protection but not in excess to cause runoff. This precise parameter control eliminates contamination.
3Reliability
If phosphated wire is coated with oil for corrosion protection, then corrosion resistance is improved, but the surface becomes greasy and sticky making handling difficult
Solution Approach 1:
The patent changes the physical state and composition parameters by using a water-based emulsion system with controlled oil distribution. This results in a non-greasy, non-sticky coating that provides corrosion protection without the handling difficulties associated with conventional oil-based coatings.
Solution Approach 2:
The patent replaces the purely oil-based mechanical coating system with a water-based emulsion system that uses surfactants to distribute oil uniformly. This substitution eliminates the greasy and sticky characteristics while maintaining the protective function.
4Ease of manufacture
If drawing agent is applied to uncoated phosphated wire, then drawing process is enabled, but dust and residue flake off causing environmental contamination
Solution Approach 1:
The patent applies the corrosion protection coating before the drawing process, creating a stable base layer that prevents dust and residue flaking during subsequent drawing operations. This preliminary coating action eliminates environmental contamination while enabling the drawing process.
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 solution provides enhanced corrosion protection, improves handling by preventing oil drips, reduces dust and residue during processing, allows for more uniform wire geometry, and enables efficient storage and transport, while being environmentally friendly and safe to handle.
Implementation Method 1
an emulsion and/or dispersion containing a surfactant and an oil as the disperse phase is applied as the corrosion inhibitor
Implementation Method 2
metal surfaces can be coated with a metal phosphate conversion layer through chemical reaction with phosphate solutions
Implementation Method 3
the drawing agent adheres better to wire coated with the corrosion inhibitor than to uncoated phosphated wire
Data Source
Figure 1~3
AI summary
The invention relates to a method for producing a phosphated wire, more particularly a steel wire, provided with an anti-corrosion agent, wherein the anti-corrosion agent is applied to the previously phosphated wire. According to the invention, an emulsion and/or dispersion containing a surfactant and, as the disperse phase, an oil or/and a wax, is applied as the anti-corrosion agent. To achieve this aim, expediently a preferably purified, paraffin oil is applied as the oil and a water-soluble soap, preferably a salt of a fatty acid having a chain length of at least 10 carbon atoms is applied as the surfactant, wherein the surfactant preferably has a salt of stearic acid or/and palmitic acid. In one embodiment of the invention, the surfactant is provided such that on application of the anti-corrosion agent to the phosphated metal surface and subsequent drying, the surfactant completely decomposes. The invention further relates to the use of an anti-corrosion agent to protect a phosphated wire, and to a phosphated wire, the surface of which is provided with an anti-corrosion agent.