Water-Based Lubricant for Plastic Processing with Blocked Maleic Anhydride
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Solution Overview
Problem
Water-based lubricants for plastic working face challenges in maintaining corrosion resistance and lubricity under high-temperature/high-humidity environments due to moisture absorption, leading to rust and degradation of dimensional accuracy and surface textures.
Innovation Solution
A water-based lubricant comprising a copolymer or homopolymer with blocked maleic anhydride moieties, an inorganic reinforcing component, and a solid lubricating component, which forms robust films with improved moisture absorption resistance and corrosion resistance, using a specific composition ratio and imidation process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If water-soluble components (water-soluble inorganic salts and water-soluble polymers) are used as lubricant components, then the lubricant has high affinity with water and good water solubility, but under high-temperature/high-humidity environments, water vapor infiltrates into the lubricating films and reaches metal surfaces to cause rusting
Solution Approach 1:
The patent uses a composite resin system comprising a water-soluble polymer and a water-insoluble polymer in specific weight ratios (0.3-3.0 and 0.7-7.0 respectively). The water-soluble polymer provides initial water solubility and film formation, while the water-insoluble polymer creates a hydrophobic barrier that prevents water vapor penetration. This composite structure resolves the contradiction by combining the benefits of both soluble and insoluble materials.
Solution Approach 2:
The patent changes the molecular weight parameters of the polymers used. Specifically, it employs a water-soluble polymer with weight-average molecular weight of 10,000-1,000,000 and a water-insoluble polymer with weight-average molecular weight of 10,000-1,000,000. By optimizing these molecular weight parameters, the lubricant achieves adequate water solubility for film formation while the higher molecular weight insulates against water vapor penetration.
2Ease of operation
If traditional oils and soaps are used as lubricants to reduce frictional force, then the lubricant can be fed as fluid lubricating films, but they involve large heat generation due to enlargement of surface area and are insufficient in lubricity for plastic working under high contact pressure
Solution Approach 1:
The patent utilizes the phase transition property of the lubricant components. The lubricant is applied as a water-based solution (liquid phase) that dries to form a solid film on the metal surface. This solid film then provides lubrication under high contact pressure without the excessive heat generation associated with fluid oils. The phase transition from liquid application to solid functionality resolves the contradiction between ease of application and energy loss.
3Reliability
If inorganic films (borax films and crystallized phosphate films) or solid films (resin films) are coated on metallic material surfaces to intervene at interfaces between dies and works, then direct contact between metals is avoided, but phosphating produces a large amount of industrial waste such as sludge causing problems in environmental conservation
Solution Approach 1:
The patent employs a water-based lubricant formulation that can be easily rinsed off after use, replacing traditional phosphating treatments that create persistent sludge waste. The lubricant forms a temporary protective film during processing that can be removed with water, avoiding the accumulation of hazardous phosphating sludge. This approach maintains seizure resistance while eliminating environmental harm.
Solution Approach 2:
The patent uses a water-based polymer lubricant as an intermediary substance that provides the necessary lubrication and protection during plastic working, replacing the phosphating process. This intermediary lubricant film achieves the same protective function (preventing metal-to-metal contact) without generating the harmful sludge byproduct associated with phosphating treatments.
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 lubricant maintains excellent lubricity and seizure resistance while preventing rust, even under high-temperature/high-humidity conditions, and allows for easy film removal and storage, addressing the limitations of existing water-soluble components.
Implementation Method 1
maleic anhydride moieties of the resin component (A) are blocked by imidation at a blocking ratio of 10 to 80%
Implementation Method 2
a lubricant composition for plastic working of metallic materials, containing (A) a synthetic resin, (B) a water-soluble inorganic salt and water, wherein (B)/(A) (mass ratio of solid content) is from 0.25/1 to 9/1 and the synthetic resin is dissolved or dispersed
Implementation Method 3
water vapor in the atmosphere will infiltrate into lubricating films and reach metal surfaces to cause rusting
Implementation Method 4
friction that is caused when metal surfaces (especially, of dies and works) intensively rub with each other may cause an increase in working energy, heat generation, seizure phenomenon and the like, for which various lubricants have been used with intent to reduce the frictional force
Implementation Method 5
friction that is caused when metal surfaces (especially, of dies and works) intensively rub with each other may cause an increase in working energy, heat generation
Data Source
Figure 1(A)~1(B)
AI summary
[Problems] To provide a water-based lubricant for plastic working excellent in moisture absorption resistance and corrosion resistance, with which degradation in lubricating performances such as lubricity, workability and seizure resistance may not occur even under high-temperature/high humidity environments. [Means for solving] A water-based lubricant for plastic working, comprising a resin component containing a copolymer or homopolymer of monomers having an ethylenically unsaturated bond, including at least maleic anhydride (A), an inorganic component (B), and a solid lubricating component (C), wherein maleic anhydride moieties of the resin component (A) are blocked with a nitrogen-containing compound at a blocking ratio of 10 to 80%, and unblocked maleic anhydride moieties are neutralized with an alkaline component at a degree of neutralization of 40 to 100%.