Water-Based Release Agent for Die-Casting Mold Lubrication
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Solution Overview
Problem
Existing release agents for die-casting molds evaporate at high temperatures, requiring cooling and re-heating, leading to increased energy consumption and material waste, and do not effectively maintain lubrication during the die-casting process.
Innovation Solution
A water-based release agent with a layer-forming component having a melting point of ≥700°C and a nonionic emulsifier component that evaporates without residue, providing lubrication and temperature stability up to 500°C, and a dispersing agent to prevent precipitation, allowing for efficient application and reduced material usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the die-casting mold is cooled down to 150°C to 250°C for applying release agent, then the release agent can wet the mold surface effectively, but the production cycle time increases and energy consumption increases due to cooling and subsequent reheating
Solution Approach 1:
The invention changes the temperature parameter at which the release agent is applied, allowing effective application at the mold's normal operating temperature (350°C) rather than requiring cooling to 150-250°C. This is achieved by formulating the release agent to remain stable and effective at higher temperatures, eliminating the need for temperature reduction and subsequent reheating, thus shortening the production cycle while maintaining wetting effectiveness.
Solution Approach 2:
The release agent is applied to the mold surface before the mold reaches its operating temperature of 350°C. The agent is applied in its liquid state at lower temperature, then the mold is heated to operating temperature, during which the release agent forms a stable protective layer. This preliminary application allows the mold to be ready for production without requiring cooling cycles.
2Reliability
If the die-casting mold is cooled down to apply release agent, then the release agent can be applied effectively, but energy consumption increases due to cooling and reheating
Solution Approach 1:
The invention modifies the release agent formulation to maintain stability and effectiveness at the mold's operating temperature of 350°C, eliminating the need to cool the mold to 150-250°C for application. This parameter change in application temperature prevents the energy-consuming cooling and subsequent reheating cycles, reducing overall energy consumption while maintaining effective release agent application.
3Temperature
If a large amount of release agent is applied to cool the mold, then the temperature can be reduced to suitable level, but material consumption increases due to evaporation
Solution Approach 1:
The invention extracts the cooling function from the release agent application process. Instead of using the release agent mixed with water for cooling purposes, the mold is cooled separately if needed, and then the release agent is applied in its concentrated form. This separation eliminates the evaporation losses associated with large amounts of water-based cooling mixtures, reducing release agent consumption while achieving the desired temperature reduction.
4Temperature
If the mold temperature falls below 150°C during cooling, then the temperature is suitable for release agent application, but the release agent is washed off by water and does not remain on the mold
Solution Approach 1:
The invention changes the formulation parameters of the release agent to enhance its thermal stability and adhesion properties. The modified release agent maintains its effectiveness and retention on the mold surface at the normal operating temperature of 350°C, eliminating the need to cool the mold below 150°C. This parameter change in formulation ensures the release agent is not washed off by water and remains on the mold surface under production conditions.
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 release agent forms a protective layer on the mold, enabling easier demolding and reducing energy and material costs by maintaining lubrication and stability throughout the die-casting process, while minimizing agent consumption and residue.
Implementation Method 1
a nonionic emulsifier component that can be evaporated without leaving any residue
Implementation Method 2
the release agent forms a protective layer on the mold
Implementation Method 3
a dispersing agent to prevent precipitation
Data Source
AI summary
The nozzle head for spray head for the application and distribution of releasing agent in die casting- or injection mold, comprises housing shell (3) in which processing chamber (4) is formed, which has a nozzle module (7) arranged between a funnel shaped opening (5) and a piston (6). A connection is formed at the housing shell to supply releasing agent by nozzle module to the funnel shaped opening, and to supply compressed air to the funnel shaped opening. The delivery rate of the releasing agent is varied by geometry of the nozzle module. The nozzle head for spray head for the application and distribution of releasing agent in die casting- or injection mold, comprises housing shell (3) in which processing chamber (4) is formed, which has a nozzle module (7) arranged between a funnel shaped opening (5) and a piston (6). A connection is formed at the housing shell to supply releasing agent by nozzle module to the funnel shaped opening, and to supply compressed air to the funnel shaped opening. The delivery rate of the releasing agent is varied by geometry of the nozzle module. The piston with its side facing the funnel shaped openings projects into the nozzles module in a closed position and locks an inlet opening formed in the housing shell for releasing agent as well as releases the entrance opening into an opened position for the releasing agent. The nozzle module is fastened in the housing shell. The nozzle module is adaptable by choice of a suitable material to a composition of the releasing agent. The surface has hardened surface faced to the piston of the nozzles module. The surface of the nozzle module is provided with a coating. Independent claims are included for: (1) a spray head; (2) a releasing agent; and (3) a method for applying and distributing a releasing agent.