Coated Welding Rod Flux Coating Without Organic Binders
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Solution Overview
Problem
The conventional production of coated brazing materials releases toxic and hazardous gases from organic binders, polluting the environment and causing welding defects due to incomplete decomposition of organic residues in welded joints, affecting the effectiveness and reliability of the joints and the service life of workpieces.
Innovation Solution
A device and method for manufacturing coated welding rods that heats a granular flux to a viscous glassy state, allowing it to adhere directly to the welding rod without using organic binders, thereby reducing environmental pollution and ensuring reliable welds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If organic binders are added to flux to form viscous paste for coating welding rods, then the flux can be applied to welding rod surfaces, but toxic and hazardous gases are released during manufacture and welding use, polluting the environment and endangering health
Solution Approach 1:
The patent extracts and removes the organic binder component from the flux coating system, replacing it with a water-based binder. This extraction eliminates the source of toxic and hazardous gases while maintaining the essential coating function, directly resolving the contradiction between ease of manufacture and harmful emissions.
Solution Approach 2:
The patent changes the chemical composition parameters of the binder from organic to water-based, fundamentally altering the material properties. This parameter change eliminates toxic gas emissions during heating while preserving the binding and coating functions, thereby resolving the environmental pollution issue without sacrificing manufacturing ease.
2Stability of the object's composition
If organic binders are used in flux coating, then the flux adheres to welding rod surfaces, but the organic binders are not completely decomposed during welding so that organic residues remain in welded joints, causing welding defects
Solution Approach 1:
The patent removes organic binders from the flux composition, extracting the harmful component that causes incomplete decomposition and residue formation. This extraction eliminates welding defects while maintaining flux adhesion through the use of water-based binders that fully decompose or evaporate during welding.
Solution Approach 2:
The patent employs a water-based binder that is designed to completely decompose or evaporate during the welding process, leaving no harmful residues. This disposable binder approach ensures that the binding function is fulfilled during coating application, but the binder itself does not persist in the final welded joint, thereby eliminating reliability issues.
3Ease of manufacture
If conventional organic binder-based flux is used, then coating can be applied to welding rods, but the organic residues affect the effectiveness and reliability of welded joints and service life of workpieces
Solution Approach 1:
The patent changes the binder composition from organic to water-based, fundamentally altering the chemical properties. This parameter change ensures complete decomposition or evaporation during welding, eliminating residues that would otherwise degrade joint reliability and workpiece service life over time, while maintaining manufacturing ease.
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 approach eliminates the use of organic binders, reducing environmental pollution and enhancing the reliability and service life of welded joints by preventing toxic gas emissions and residue formation during the welding process.
Implementation Method 1
each heating device is configured to heat the welding rod in the grabbing device
Implementation Method 2
the heated welding rod is configured such that a flux surrounding the welding rod is heated to become a viscous glassy state
Implementation Method 3
the heated welding rod is configured such that a flux surrounding the welding rod is heated to become a viscous glassy state
Implementation Method 4
the heated welding rod is configured such that a flux surrounding the welding rod is heated to become a viscous glassy state
Implementation Method 5
the flux in the viscous glassy state adheres to a surface of the welding rod
Data Source
AI summary
The present disclosure provides a device and method for manufacturing a coated welding rod. The device for manufacturing a coated welding rod includes a grabbing device, a heating device, and a flux storage device. The heating device is configured to heat a welding rod in the grabbing device. A flux in granular form is stored in the flux storage device, the grabbing device is configured to transport the heated welding rod into the flux storage device, and the heated welding rod is configured to heat the flux surrounding the welding rod into a viscous glassy state so that the flux in the viscous glassy state adheres to the surface of the welding rod. The heated welding rod enables the granular flux to be formed into a viscous glassy state so that the flux can be adhered directly to the surface of the welding rod.