Press Tool Wear Layer with Embedded Release Agent
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Solution Overview
Problem
Existing pressing tools often suffer from adhesion issues with workpieces, leading to residue and reduced quality, as they lack effective release agents, and their production can be environmentally unfriendly due to the use of chromium layers.
Innovation Solution
A pressing tool with a wear layer that includes a full-surface and partial wear layer, where a release agent is embedded to reduce adhesion, and mineral particles are used to enhance wear resistance, allowing for different gloss levels and potentially chromium-free production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a chromium layer is used on the pressing surface, then wear resistance is improved, but environmental friendliness deteriorates
Solution Approach 1:
The patent changes the material composition parameters by using a nickel-based wear layer instead of chromium, and incorporates specific release agents (fluorinated compounds, silicones, or waxes) to achieve the desired release properties without harmful chromium
Solution Approach 2:
The patent creates a composite wear layer combining nickel base material with embedded release agents (such as perfluorinated compounds, silicones, or waxes), achieving both wear resistance and effective release properties in a single integrated layer
2Object-generated harmful factors
If a release agent is added during pressing, then adhesion reduction is improved, but device complexity increases
Solution Approach 1:
The release agent is incorporated into the wear layer during manufacturing, so the release function is already prepared in advance. This eliminates the need to add release agents during the pressing process, simplifying the overall process
Solution Approach 2:
The patent combines the wear resistance function and the release function into a single integrated wear layer, eliminating the need for separate release agent application steps and reducing process complexity
3Manufacturing precision
If the pressing surface is made smooth, then manufacturing precision is improved, but adhesion to workpiece increases
Solution Approach 1:
The patent creates local quality variations within the wear layer by incorporating release agents that create microscopically rough or heterogeneous surfaces, providing low adhesion areas while maintaining overall surface smoothness for manufacturing precision
Solution Approach 2:
The patent changes the surface energy parameters of the pressing surface by incorporating release agents (fluorinated compounds, silicones, waxes) that reduce surface energy and adhesion, allowing smooth surfaces to have low adhesion properties
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 tool effectively reduces adhesion to workpieces, enhancing product quality and environmental sustainability by eliminating the need for additional release agents and chromium layers, while maintaining wear resistance through embedded mineral particles.
Implementation Method 1
a release agent is embedded, which at least reduces adhesion of the wear layer to the workpiece during pressing
Implementation Method 2
mineral particles are used to enhance wear resistance
Implementation Method 3
The different gloss levels of the wear layers, which are formed as paint or plastic layers, can be achieved, for example, by hardening the wear layers, e.g., through UV irradiation
Implementation Method 4
by hardening the wear layers, e.g., through UV irradiation, electron beam or laser curing
Implementation Method 5
by hardening the wear layers, e.g., through UV irradiation, electron beam or laser curing
Implementation Method 6
the press tool is preferably manufactured by applying the metal layer to the base structure with the addition of the release agent by electroplating or chemical coating
Implementation Method 7
the press tool is preferably manufactured by applying the plastic layer to the base structure and adding the release agent by printing
Data Source
Figure 1~2
Figure 3~4
AI summary
The invention relates to a press tool (1) for producing a workpiece. The press tool (1) comprises a main structure (10), a pressing surface (2) and a wear layer (11, 31) provided on the main structure (10) and forming, at least in part, the pressing surface (2), which wear layer comes into contact with the workpiece during the manufacture of the latter by compression and in which wear layer a release agent (12) is embedded, which, during the compression process, at least reduces the adhesion of the wear layer (11, 31) to the workpiece.