Coating material and coating for compressor, compressor, crankshaft, and method for forming coating on surface of substrate

Abstract

The present application relates to the technical field of compressors. Disclosed is a coating material for a compressor. The coating material comprises graphite, carbon fibers and nanoparticles. Further disclosed in the present application are a coating for a compressor, a compressor, a crankshaft, and a method for forming a coating on the surface of a substrate.

Description

Coating, coating layer for compressor, compressor, crankshaft and method for forming coating layer on surface of base body

[0001] The present application is based on the Chinese patent application No. 202411375577.0, filed on September 29, 2024, and the Chinese patent application No. 202422390692.7, filed on September 29, 2024, and claims priority to the Chinese patent application No. 202411375577.0 and the Chinese patent application No. 202422390692.7, the contents of which are hereby incorporated by reference in their entirety. TECHNICAL FIELD

[0002] The present application relates to the technical field of compressors, in particular to a coating for a compressor, a coating layer for a compressor, a compressor, a crankshaft and a method for forming a coating layer on a surface of a base body. BACKGROUND

[0003] At present, with the fierce cost competition in the air conditioner market, miniaturization and high speed of air conditioner compressors have become a trend. However, the crankshaft of the compressor is prone to wear under high speed working condition.

[0004] In the process of implementing the embodiments of the present disclosure, it is found that at least the following problems exist in the related art:

[0005] In the related art, the anti-wear coating is more suitable for low-speed compressors and cannot meet the lubrication and wear resistance requirements of high-speed compressors. The anti-wear coating will wear off after a period of use, which will cause the base body of the part to wear and thus cause the part to fail and the compressor to be damaged. SUMMARY

[0006] To provide a basic understanding of some aspects of the disclosed embodiments, the following summary is given. The summary is not an overall description of the application, nor is it intended to determine key / important elements or delineate the scope of protection of these embodiments, but as a prelude to the detailed description below.

[0007] The embodiments of the present disclosure provide a coating for a compressor, a coating layer for a compressor, a compressor, a crankshaft and a method for forming a coating layer on a surface of a base body, which solves the problem of how to improve the wear resistance of the base body of a high-speed compressor.

[0008] In some embodiments, the coating for a compressor comprises graphite, carbon fiber and nanoparticles.

[0009] In some embodiments, the coating layer for a compressor is formed by the coating of any one of the preceding embodiments.

[0010] In some embodiments, the compressor comprises a base body, and the surface of the base body is provided with the coating layer described above; wherein the coating layer forms a first coating layer on the surface of the base body.

[0011] In some embodiments, the crankshaft for the compressor, the surface of the crankshaft is provided with a first coating layer formed by the coating material according to any one of the preceding embodiments, and the friction coefficient of the first coating layer is less than the friction coefficient of the crankshaft.

[0012] In some embodiments, the method for forming a coating layer on the surface of a substrate comprises the following steps: spraying the coating material according to any one of the preceding embodiments on the surface of the substrate; placing the substrate in an incubator to volatilize the solvent; and placing the substrate in a high-temperature oven to cure the coating material.

[0013] The foregoing general description and the following description are merely exemplary and explanatory, and are not intended to limit the present application. BRIEF DESCRIPTION OF DRAWINGS

[0014] One or more embodiments are illustrated by way of example in the accompanying drawings, which are not intended to limit the embodiments and the drawings do not constitute a limitation of the embodiments, elements having the same reference numbers in the drawings show similar elements, the drawings do not constitute a proportional limitation, and wherein:

[0015] Fig. 1 is a cross-sectional view of a compressor according to an embodiment of the present disclosure;

[0016] Fig. 2 is a structural schematic view of a crankshaft according to an embodiment of the present disclosure;

[0017] Fig. 3 is a structural schematic view of a substrate surface provided with a first coating layer according to an embodiment of the present disclosure;

[0018] Fig. 4 is a structural schematic view of a substrate surface provided with a first coating layer and a second coating layer according to an embodiment of the present disclosure.

[0019] Reference numerals: 10: compressor; 20: substrate; 21: crankshaft; 211: long shaft; 212: short shaft; 30: first coating layer; 31: second coating layer. DETAILED DESCRIPTION

[0020] In order to enable a more detailed understanding of the features and technical content of the embodiments of the present disclosure, the implementation of the embodiments of the present disclosure will be described in detail below with reference to the accompanying drawings, which are only used for reference and do not constitute a limitation of the embodiments of the present disclosure. In the following technical description, in order to facilitate explanation, a plurality of details are provided to provide a full understanding of the disclosed embodiments. However, one or more embodiments can still be implemented without these details. In other cases, well-known structures and devices can be simplified to facilitate the drawings.

[0021] The terms "first", "second", etc. in the description, claims, and drawings of the embodiments of the present disclosure, and the above-described drawings are used to distinguish similar objects, and do not necessarily have to be used to describe a specific order or sequence. It should be understood that the data thus used can be interchanged under appropriate circumstances, so that the embodiments of the present disclosure described herein can be implemented. In addition, the terms "include" and "have" and any variations thereof are intended to cover non-exclusive inclusion.

[0022] In the embodiments of the present disclosure, the terms "upper", "lower", "inner", "middle", "outer", "front", "back", and the like indicate the orientation or positional relationship based on the orientation or positional relationship shown in the drawings. These terms are mainly used to better describe the embodiments of the present disclosure and its embodiments, and are not used to limit the indicated devices, elements or components to have a specific orientation, or to be constructed and operated in a specific orientation. In addition, in addition to indicating the orientation or positional relationship, the above-mentioned part of the terms can also be used to represent other meanings, for example, the term "upper" can also be used to represent a certain dependent relationship or connection relationship in some cases. For those skilled in the art, the specific meanings of these terms in the embodiments of the present disclosure can be understood according to the specific circumstances.

[0023] In addition, the terms "set", "connected", "fixed" should be broadly understood. For example, "connected" can be fixedly connected, detachably connected, or integrally configured; can be mechanically connected, or electrically connected; can be directly connected, or indirectly connected through an intermediate medium, or internal communication between two devices, elements or components. For those skilled in the art, the specific meanings of the above terms in the embodiments of the present disclosure can be understood according to the specific circumstances.

[0024] Unless otherwise specified, the term "a plurality of" means two or more.

[0025] In the embodiments of the present disclosure, the character " / " represents an "or" relationship between the objects before and after it. For example, A / B represents: A or B.

[0026] The term "and / or" is a description of the association between objects, which means that there can be three relationships. For example, A and / or B, which means: A or B, or, A and B, the three relationships.

[0027] It should be noted that the embodiments in the embodiments of the present disclosure and the features in the embodiments can be combined with each other without conflict.

[0028] At present, with the white-hot cost competition in the air conditioner market, miniaturization and high-speed rotation of air conditioner compressors have become a trend. However, the crankshaft of the compressor is prone to wear under high-speed working conditions.

[0029] The related art provides an anti-wear surface coating by applying a precursor powder material to a wear surface of a metal component of a scroll or rotary compressor by spraying. The precursor powder material includes a powdered thermoplastic polymer, first lubricant particles, and second lubricant particles, which are heated to form a substantially uniform coating having a thickness of less than or equal to about 0.006 inches that covers the underlying metal component. Scroll compressor components having wear surfaces coated with the anti-wear coating can include hubs or bushings that interface with flat portions of a crankshaft having the anti-wear coating to improve overall performance and reduce wear. The anti-wear coating of the related art is more suitable for low speed compressors and cannot meet the lubrication and wear resistance requirements of high speed compressors. The anti-wear coating wears off after a period of use, which can cause wear of the base of the part and further cause failure of the part and damage to the compressor.

[0030] To improve the wear resistance of the base 20 of the high speed compressor 10, the embodiments of the present disclosure provide a coating for the compressor 10, which includes graphite, carbon fibers, and nanoparticles.

[0031] The graphite, as a solid lubricant, can reduce the friction coefficient and enhance the lubricity of the coating, thereby reducing the wear of the surface of the base 20 during operation. The graphite also has excellent thermal conductivity, which can form a good heat conduction effect in the coating and help dissipate heat, thereby enhancing the thermal stability of the coating. The carbon fibers provide additional strength and toughness to the coating. The nanoparticles have a small size and a high specific surface area, which can form a dense protective layer and further enhance the wear resistance and corrosion resistance of the coating.

[0032] The coating for the compressor 10 provided by the embodiments of the present disclosure is mixed with graphite, carbon fibers, and nanoparticles, so that the coating has good self-lubricating properties and can effectively improve the anti-friction of the coating. The coating is applied to the compressor 10, which can form a uniform and dense protective coating on the surface of the base 20. The coating has a low friction coefficient and high wear resistance, which can reduce the friction and wear of the surface of the base 20 under high speed working conditions, thereby prolonging the maintenance period and service life of the compressor 10.

[0033] Optionally, the nanoparticles are organic resins.

[0034] The use of organic resins as nanoparticles can improve the wear resistance of the coating while providing better adhesion and chemical stability to the coating, thereby improving the bonding strength of the coating to the surface of the base 20. This can improve the durability of the coating, thereby prolonging the service life of the coating formed by the coating.

[0035] It can be understood that silica nanoparticles, silicon carbide nanoparticles, and other nanoparticles can also improve the wear resistance of the coating.

[0036] Optionally, the paint further comprises a solvent, and the solvent comprises N-methyl-2-pyrrolidone.

[0037] N-methyl-2-pyrrolidone has good solubility and chemical stability, and can better dissolve the nanoparticles, and can also dissolve the graphite and the carbon fibers at the same time. In this way, the uniformity and the leveling property of the paint can be improved, and the paint can be uniformly coated on the surface of the base body 20. At the same time, the volatility of N-methyl-2-pyrrolidone is low, and it will not evaporate too fast during the drying of the paint, which helps to form a uniform coating of the paint on the surface of the base body 20. In addition, the chemical stability of the solvent helps to protect the paint from chemical reactions during the painting process.

[0038] Optionally, the paint further comprises an organic binder.

[0039] The organic binder can form a firm chemical bond with the graphite, the carbon fibers and the nanoparticles, thereby enhancing the cohesion of the components of the paint. The organic binder can also form a firm chemical bond with the surface of the base body 20, thereby enhancing the adhesion of the paint on the surface of the base body 20. The organic binder can be silicone resin, epoxy resin or polyurethane, etc.

[0040] Optionally, the concentration of the graphite ranges from 8% to 30%, the concentration of the carbon fibers is less than or equal to 10%, and the concentration of N-methyl-2-pyrrolidone ranges from 30% to 60%.

[0041] The concentration described in the embodiments of the present disclosure refers to the volume percentage concentration.

[0042] When the concentration of the graphite is greater than or equal to 8%, the friction coefficient of the paint can be reduced, thereby reducing the wear rate of the coating formed by the paint and improving the wear resistance of the coating. The graphite particles form a physical barrier in the paint, which helps to disperse the surface stress. The paint forms a coating on the surface of the base body 20, which can reduce the wear of the coating. When the concentration of the graphite is less than or equal to 30%, the dispersion of the stress of the paint can be improved, and the brittleness of the coating caused by too high concentration of the graphite can be prevented, and the wear resistance of the coating can be reduced.

[0043] When the concentration of the carbon fibers is less than or equal to 10%, the mechanical strength and the wear resistance of the paint can be improved, and the decrease of the flowability of the paint caused by the increase of the content of the carbon fibers can be prevented, and the uniformity of the coating can be avoided. Controlling the concentration of the carbon fibers to be less than or equal to 10% can also reduce the cost of the paint.

[0044] When the concentration of N-methyl-2-pyrrolidone is greater than or equal to 30%, the components such as graphite, carbon fiber and nanoparticles can be better dissolved and dispersed in N-methyl-2-pyrrolidone to form a uniform mixture, thereby improving the leveling property of the coating and the uniformity of the coating. When the concentration of N-methyl-2-pyrrolidone is less than or equal to 60%, the viscosity of the coating can be reduced to avoid affecting the flowability of the coating, and the cost of the coating can also be reduced.

[0045] The concentration of graphite, carbon fiber and N-methyl-2-pyrrolidone in the coating is controlled within a suitable range, and a specific concentration ratio is formed among graphite, carbon fiber and N-methyl-2-pyrrolidone, so that the rheological property of the coating and the mechanical strength of the coating can be optimized, and the uniformity and stability of the coating can be improved.

[0046] It can be understood that the concentration of graphite can be 8%, 10%, 12%, 15%, 20%, 25%, 30%, the concentration range of carbon fiber can be 1%, 2%, 3%, 4%, 5%, 6%, 7%, 8%, 9%, 10%, and the concentration of N-methyl-2-pyrrolidone can be 30%, 35%, 40%, 45%, 50%, 55%, 60%.

[0047] Optionally, the concentration of graphite is 15%, the concentration of carbon fiber is 2%, and the concentration of N-methyl-2-pyrrolidone is 50%.

[0048] Optionally, the concentration of graphite is 25%, the concentration of carbon fiber is 8%, and the concentration of N-methyl-2-pyrrolidone is 60%.

[0049] In this way, a specific concentration ratio is formed among graphite, carbon fiber and N-methyl-2-pyrrolidone, and the coating is provided with better wear resistance, adhesion, uniformity and chemical stability.

[0050] Optionally, the concentration range of nanoparticles is 1% to 15%.

[0051] Optionally, the concentration range of nanoparticles is 1% to 10%.

[0052] Optionally, the concentration range of graphite is 8% to 30%, the concentration range of carbon fiber is less than or equal to 10%, the concentration range of N-methyl-2-pyrrolidone is 30% to 60%, and the concentration range of nanoparticles is 1% to 15%. The concentrations of the components add up to 100%.

[0053] When the nanoparticle concentration is greater than or equal to 1%, the ultra-small size and high specific surface area of the nanoparticles can initially form a dense physical barrier in the coating, covering the substrate surface micro-defects, and thus improve the wear resistance and corrosion resistance of the coating by forming a basic protective layer. When the organic resin nanoparticle concentration is greater than or equal to 1%, the organic resin nanoparticles can form basic chemical bonds with the substrate surface and other components (such as graphite and carbon fibers) in the coating, thereby improving the adhesion of the coating.

[0054] When the nanoparticle concentration is less than or equal to 15%, the nanoparticles can be prevented from excessive agglomeration, which can cause the viscosity of the coating to increase rapidly, thereby avoiding affecting the leveling and uniform coating ability of the coating, and thus avoiding the deterioration of the performance of the coating. In addition, the coating can also avoid excessive rigidity and reduced toughness, and prevent the coating from being easily cracked, thereby maintaining the comprehensive mechanical properties of the coating. When the organic resin nanoparticle concentration is less than or equal to 15%, the chemical stability problem caused by excessive concentration can be avoided, such as the accelerated aging of the coating caused by excessive cross-linking of the organic resin.

[0055] Optionally, the nanoparticle concentration is 7%.

[0056] Optionally, the concentration of graphite is 25%, the concentration of carbon fibers is 8%, the concentration of N-methyl-2-pyrrolidone is 60%, and the concentration of nanoparticles is 7%.

[0057] The 7% concentration of nanoparticles can form a composite network structure with the 25% concentration of graphite and the 8% concentration of carbon fibers, thereby improving the balance between the wear resistance and lubricity of the coating. The 25% concentration of graphite can form a continuous lubricating network of graphite layers, thereby reducing the friction coefficient. The 8% concentration of carbon fibers can enhance the toughness of the coating by bridging, thereby improving the impact strength of the coating. The 7% concentration of nanoparticles can fill the gaps between the graphite layers, thereby forming a lubricating-supporting composite structure. The 60% concentration of N-methyl-2-pyrrolidone as a good solvent can uniformly disperse the graphite layers and carbon fibers. At the same time, the 7% concentration of nanoparticles can be fully dissolved and dispersed in the 60% concentration of N-methyl-2-pyrrolidone solvent, thereby avoiding particle sedimentation or agglomeration, and thus enabling the coating to be uniformly coated on the substrate surface to form a dense coating with uniform thickness and no defects. The concentration ratio can achieve a balance between low friction, high wear resistance, and long service life under high-speed working conditions through the multi-scale synergy between the lubricating phase (graphite), the reinforcing phase (carbon fibers), the functional phase (nanoparticles), and the medium phase (N-methyl-2-pyrrolidone).

[0058] The coating for the compressor 10 is formed by the coating as described in any one of the above embodiments.

[0059] The coating for the compressor 10 provided by the embodiments of the present disclosure has all the beneficial effects of the coating as described in any of the above embodiments.

[0060] The layered structure of graphite can form a natural sliding layer in the coating, making the surface of the coating smoother, thereby effectively reducing the energy loss and part wear of the compressor 10. The high strength and high modulus characteristics of carbon fibers make the coating less likely to break when subjected to high loads, thereby improving the stability and durability of the coating in the high-speed environment of the compressor 10. The nanoparticles can form a dense protective layer in the coating due to their ultra-small size and high specific surface area, effectively resisting the erosion of external corrosive media, while also improving the hardness and wear resistance of the coating.

[0061] The coating provided by the embodiments of the present disclosure has low friction coefficient, extremely high wear resistance, high bonding strength with the metal substrate 20, wide temperature range for use, strong corrosion resistance, good oil and fat resistance, and other characteristics. The coating provided by the embodiments of the present disclosure can be firmly attached to the surface of the substrate 20 of the compressor 10 parts, significantly reducing the friction and wear between the part substrates 20, reducing the heat generated by friction, thereby prolonging the maintenance cycle and service life of the compressor 10.

[0062] In combination with FIGS. 1-4, the embodiments of the present disclosure provide a compressor 10 comprising a substrate 20, the surface of the substrate 20 being provided with a coating as described in the above embodiments; wherein the coating as described in the above embodiments forms a first coating 30 on the surface of the substrate 20.

[0063] The surface of the substrate 20 is provided with a coating as described in the above embodiments, which can be a coating as described in the above embodiments directly coated on the surface of the substrate 20, and the formed first coating 30 is in direct contact with the surface of the substrate 20. Alternatively, the coating as described in the above embodiments can be arranged on the surface of the substrate 20 in an interval, and the formed first coating 30 is not in direct contact with the surface of the substrate 20, and a second coating 31 can be arranged between the first coating 30 and the surface of the substrate 20.

[0064] The compressor 10 provided by the embodiments of the present disclosure has all the beneficial effects of the coating as described in the above embodiments. The coating comprising graphite, carbon fibers and nanoparticles forms a first coating 30 on the surface of the substrate 20, which provides direct protection to the substrate 20, reduces the possibility of direct contact wear and corrosion between the substrates 20, thereby improving the wear resistance of the substrate 20 of the high-speed compressor 10. The substrate 20 can be a crankshaft 21, a piston, a cylinder or other parts in the compressor 10.

[0065] Alternatively, the thickness of the first coating 30 ranges from 5 μm to 15 μm.

[0066] The thickness of the first coating layer 30 is greater than or equal to 5 μm, so that the first coating layer 30 has sufficient thickness to enhance wear resistance and durability, to provide sufficient protection for the base body 20, thereby prolonging the service life of the first coating layer 30.

[0067] The thickness of the first coating layer 30 is less than or equal to 15 μm, so that the flexibility of the first coating layer 30 can be maintained, and the first coating layer 30 can better adapt to the slight deformation of the base body 20, and the cracking of the first coating layer 30 caused by thermal expansion and contraction or mechanical vibration of the base body 20 can be reduced. The thinner thickness can also improve the adhesion between the first coating layer 30 and the base body 20, thereby reducing the risk of the first coating layer 30 falling off.

[0068] The thickness of the first coating layer 30 is limited to 5 μm to 15 μm in the embodiment of the present disclosure, so that the base body 20 of the compressor 10 can be provided with sufficient protection to prevent the base body 20 from being worn and corroded, and at the same time, the first coating layer 30 can also be prevented from being too thick and heavy to affect the movement performance of the base body 20.

[0069] It can be understood that the thickness of the first coating layer 30 can be 5 μm, 8 μm, 10 μm, 12 μm, or 15 μm.

[0070] Optionally, the thickness of the first coating layer 30 is 8 μm.

[0071] When the thickness of the first coating layer 30 is 8 μm, the wear resistance, adhesion, and flexibility of the first coating layer 30 can be balanced, and the surface of the base body can be better protected.

[0072] Optionally, in combination with FIG. 4, the surface of the base body 20 is further provided with a second coating layer 31, and the second coating layer 31 is arranged between the surface of the base body 20 and the first coating layer 30.

[0073] The surface of the base body 20 is first provided with the second coating layer 31, and then the surface of the base body 20 is treated by using the coating material disclosed in the above embodiments on the basis of the second coating layer 31, and the first coating layer 30 is formed outside the second coating layer 31. The second coating layer 31 is arranged between the surface of the base body 20 and the first coating layer 30, and provides an additional protective layer for the base body 20, thereby enhancing the corrosion resistance and wear resistance of the base body 20. The double-layer coating structure provides stronger wear-resistant protection for the base body 20, thereby prolonging the service life of the base body 20.

[0074] It can be understood that the surface of the base body 20 can be provided only with the first coating layer 30, or can be provided with both the first coating layer 30 and the second coating layer 31.

[0075] Optionally, the second coating layer 31 is formed by a phosphating process.

[0076] The surface of the base body 20 is first subjected to phosphating treatment to form a uniform and dense phosphating film on the surface of the base body 20, thereby forming the second coating layer 31. The phosphating film as the second coating layer 31 is arranged between the surface of the base body 20 and the first coating layer 30, and can form good chemical bonding with the surface of the base body 20 and the second coating layer 31. In this way, the adhesion of the second coating layer 31 and the first coating layer 30 can be enhanced, and the risk of peeling of the second coating layer 31 and the first coating layer 30 can be reduced. At the same time, the phosphating film has high hardness and good lubricity, which can effectively reduce the wear of the second coating layer 31 and improve the wear resistance. The surface of the base body 20 can be subjected to phosphating treatment by using a manganese phosphate coating agent.

[0077] Optionally, the thickness of the second coating layer 31 is 2 μm to 5 μm.

[0078] When the thickness of the second coating layer 31 is greater than or equal to 2 μm, the second coating layer 31 has sufficient thickness to form lubrication and protection on the surface of the base body 20, can withstand greater friction, and can reduce the wear of the surface of the second coating layer 31. When the thickness of the second coating layer 31 is greater than or equal to 2 μm, the second coating layer 31 can more effectively isolate the base body 20 from the corrosive medium, thereby improving the corrosion resistance of the base body 20. In this way, the service life and effect of the second coating layer 31 can be prolonged, and the wear resistance and corrosion resistance of the base body 20 can be improved. At the same time, the second coating layer 31 serves as an intermediate layer between the surface of the base body 20 and the first coating layer 30, and the porous structure of the phosphating film can enhance the bonding force with the surface of the base body 20 and the first coating layer 30. The second coating layer 31 with sufficient thickness can enhance the adhesion and durability of the coating structure.

[0079] When the thickness of the second coating layer 31 is less than or equal to 5 μm, the second coating layer 31 can avoid being too thick, so that uniform coating can be more easily achieved, and the uniformity of the coating can be improved. The second coating layer 31 with a smaller thickness can better adapt to the slight deformation of the base body 20, reduce the cracking of the coating caused by thermal expansion and contraction or mechanical vibration of the base body 20, and thereby improve the durability of the second coating layer 31. At the same time, the second coating layer 31 with a smaller thickness can be formed in a shorter time, which helps to improve the efficiency of surface treatment of the base body 20 and speed up the production.

[0080] The thickness of the second coating layer 31 is limited to 2 μm to 5 μm in the embodiments of the present disclosure, which can improve the uniformity and consistency of the second coating layer 31, and at the same time, can avoid the second coating layer 31 being too thick to affect the performance of the base body 20.

[0081] It can be understood that the thickness of the second coating layer 31 can be 2 μm, 3 μm, 4 μm, or 5 μm.

[0082] Optionally, the thickness of the second coating layer 31 is 3 μm.

[0083] When the thickness of the second coating layer 31 is 3 microns, the wear resistance, adhesion and flexibility of the second coating layer 31 can be balanced, and the surface of the base body 20 can be better protected.

[0084] Optionally, the thickness of the second coating layer 31 is 2 microns to 5 microns, and the thickness of the first coating layer 30 is 5 microns to 15 microns.

[0085] The embodiments of the present disclosure simultaneously limit the thickness of the second coating layer 31 to be 2 microns to 5 microns and the thickness of the first coating layer 30 to be 5 microns to 15 microns, so that the first coating layer 30 and the second coating layer 31 can realize the combination of the two coating layers through appropriate thickness. In this way, better comprehensive performance can be provided for the two-layer coating structure, including wear resistance, corrosion resistance, heat resistance, etc., so as to improve the protection effect and service life of the base body 20.

[0086] The thickness of the first coating layer 30 is 5 microns to 15 microns, and the thicker first coating layer 30 provides a stronger wear-resistant layer, and the appropriate thickness of the second coating layer 31 helps to further improve the overall wear resistance while maintaining the flexibility and adhesion of the overall coating structure. The thicker first coating layer 30 can serve as the main corrosion-resistant layer, and the second coating layer 31 can provide an auxiliary protective layer to enhance the blocking effect of corrosive media. The thickness of the second coating layer 31 is 2 microns to 5 microns, and the second coating layer 31 serves as an intermediate layer between the base body 20 and the first coating layer 30. The second coating layer 31 is thinner than the first coating layer 30, which helps to improve the adhesion between the base body 20 and the first coating layer 30 and enhance the adhesion stability between the base body 20 and the first coating layer 30 and the second coating layer 31.

[0087] Optionally, in combination with the embodiments shown in FIGS. 1 to 4, the base body 20 includes a crankshaft 21, and the surface of the crankshaft 21 is provided with the first coating layer 30.

[0088] In the high-speed compressor 10, the crankshaft 21 is a key rotating component, and its performance directly affects the stability and service life of the entire compressor 10. By providing the first coating layer 30 on the surface of the crankshaft 21, the first coating layer 30 has low friction coefficient, extremely high wear resistance, wide use temperature range, strong corrosion resistance, good oil and fat resistance, etc., which can improve the wear resistance of the crankshaft 21 in the high-speed compressor 10. The first coating layer 30 and the second coating layer 31 can also be provided on the surface of the crankshaft 21 at the same time, and the double-layer coating structure can more effectively improve the lubricity and wear resistance of the surface of the crankshaft 21. At the same time, the corrosion resistance of the surface of the crankshaft 21 can also be improved, and the crankshaft 21 is provided with more comprehensive protection.

[0089] Optionally, the material of the base body 20 is nodular cast iron material or steel material.

[0090] The material of the base body 20 is ductile cast iron or steel material, which can enhance the high strength, toughness and wear resistance of the base body 20, so that the base body 20 can stably operate under high load and high speed conditions. The first coating layer 30 also has the characteristic of high bonding strength with the metal base body 20. The first coating layer 30 is arranged on the surface of the base body 20 made of ductile cast iron or steel material, which can make the first coating layer 30 more firmly adhere to the surface of the base body 20. When the base body 20 is a crankshaft 21, the crankshaft 21 made of ductile cast iron or steel material can realize long-term stable operation and high-efficiency operation of the crankshaft 21, which provides a strong guarantee for the overall performance and reliability of the compressor 10.

[0091] The embodiment of the present disclosure provides a crankshaft 21 for a compressor. The surface of the crankshaft 21 is provided with a first coating layer formed by the coating material according to any one of the above-mentioned embodiments. The friction coefficient of the first coating layer is less than that of the crankshaft.

[0092] The friction coefficient of the first coating layer 30 is less than that of the crankshaft 21, so that the first coating layer 30 has better wear resistance than the crankshaft 21. Arranging the first coating layer 30 on the surface of the crankshaft 21 can avoid the possibility of direct contact and wear between the surface of the crankshaft 21 and other components of the compressor 10, and can effectively improve the anti-friction and fatigue resistance of the crankshaft 21. Under high-speed working conditions, the high wear-resistant protection of the first coating layer 30 can effectively avoid the friction and wear of the crankshaft 21, thereby prolonging the maintenance period and service life of the crankshaft 21.

[0093] The embodiment of the present disclosure provides a method for forming a coating layer on the surface of a base body 20. The method comprises the following steps: spraying the coating material according to the above-mentioned embodiments on the surface of the base body 20; placing the base body 20 in a heat preservation box to volatilize the solvent; and placing the base body 20 in a high-temperature oven to solidify the coating material.

[0094] The coating material according to the above-mentioned embodiments is attached to the surface of the base body 20 by spraying. The spraying process is not only simple to operate, but also can realize rapid coverage of the coating material and form a uniform coating layer. Here, the coating material can be directly sprayed on the surface of the base body 20 to directly adhere the first coating layer 30 on the surface of the base body 20. The base body 20 coated with the coating material is placed in a heat preservation box to volatilize the solvent, which can improve the quality of the coating layer. Then, the base body 20 is placed in a high-temperature oven for solidification. The high-temperature environment makes the high molecular chains in the coating material crosslink, forming a strong and stable protective layer. This can realize the close combination and uniform distribution of the solidified coating layer with the base body 20, effectively realize the wear resistance, corrosion resistance and high-temperature resistance of the coating layer, thereby improving the protection effect and service life of the first coating layer 30.

[0095] Exemplarily, the method for forming the coating layer on the surface of the base 20 comprises the following steps. First, the surface of the base 20 is cleaned to remove oil. Then, the coating material described in the above examples is stirred uniformly, the base 20 is placed on a special spraying tool to rotate, and the stirred coating material is sprayed on the surface of the base 20 by the equipment. The base 20 is placed to rotate, which can uniformly and comprehensively spray the coating material on the surface of the base 20 to form the first coating layer 30. In this way, the spraying efficiency is improved, and the uniformity of the first coating layer 30 is also improved. After spraying, the base 20 is placed in a heat preservation box to volatilize the solvent, and then the base 20 is placed in a high-temperature oven to solidify the coating material, and finally the base 20 is taken out and naturally cooled to room temperature. In this way, a firm first coating layer 30 can be formed on the surface of the base 20, thereby forming a wear-resistant protective layer on the base 20 under the high-speed operation of the compressor 10.

[0096] Optionally, the temperature of the heat preservation box is set to 80°C, and the base 20 is placed in the heat preservation box for 30 minutes.

[0097] The volatilization speed of the solvent at 80°C is moderate, which allows sufficient time for the solvent in the coating material to be uniformly distributed, thereby forming a uniform film thickness of the coating layer and avoiding defects such as pinholes and orange peel phenomenon caused by rapid volatilization of the solvent. The heat preservation time of 30 minutes allows the solvent to volatilize slowly, reducing bubbles and unevenness on the surface of the coating layer, thereby improving the quality and appearance of the coating layer. The appropriate solvent volatilization condition helps to improve the adhesion between the coating layer and the base 20, because the slow volatilization of the solvent can reduce the stress in the coating layer, thereby enhancing the durability and protective performance of the coating layer.

[0098] At the same time, setting the solvent volatilization temperature to 80°C can also avoid affecting the structure of graphite, carbon fibers and nanoparticles in the coating material. At a lower volatilization temperature, graphite, carbon fibers and nanoparticles in the coating material are not easy to aggregate or settle, maintaining the uniformity and stability of the coating material.

[0099] In the case of N-methyl-2-pyrrolidone as the solvent, placing the base 20 at 80°C for 30 minutes can allow the N-methyl-2-pyrrolidone to volatilize sufficiently. This operating condition can effectively control the volatilization speed of the N-methyl-2-pyrrolidone, achieving uniform coating layer while improving production efficiency.

[0100] Optionally, the temperature of the high-temperature oven is set to 210°C, and the base 20 is placed in the high-temperature oven for 1 hour.

[0101] The substrate 20 with the coating attached after solvent evaporation is placed in a high-temperature oven, set to 210°C and kept for 1 hour for curing of the coating. The high temperature of 210°C can promote the intermolecular forces of the organic binder with the surface of the substrate 20, forming stronger chemical bonds, so high-temperature curing helps to enhance the adhesion between the coating and the surface of the substrate 20. High-temperature baking helps to completely evaporate the solvents and other low-molecular-weight components in the paint, reducing the porosity and defects in the coating, thereby improving the density and corrosion resistance of the coating. At the same time, the coating cured in a high-temperature environment has better thermal stability. In addition, at a high temperature of 210°C, the organic binder in the paint will also undergo a chemical reaction to form a three-dimensional network structure, achieving complete curing of the coating, which can improve the hardness and wear resistance of the first coating 30.

[0102] The disclosure embodiment limits the curing time to 1 hour to ensure uniform curing of each part of the coating, avoiding performance differences caused by uneven curing, and improving the uniformity and consistency of the first coating 30.

[0103] The temperature of the high-temperature oven is set to 210°C, and the substrate 20 is placed for 1 hour, which helps to achieve complete curing of the coating and improve the mechanical properties and adhesion of the coating. At the same time, it can improve the uniformity and appearance quality of the coating, improve the protection effect of the surface of the substrate 20 and prolong its service life.

[0104] Optionally, before the paint is sprayed on the surface of the substrate 20, it further comprises: sandblasting or phosphating treatment on the surface of the substrate 20.

[0105] Before the paint is sprayed on the surface of the substrate 20, the surface of the substrate 20 is sandblasted, which not only effectively cleans the surface of the substrate 20, but also forms micro-roughness on the surface of the substrate 20 through physical action, thereby enhancing the adhesion of the first coating 30 to the surface of the substrate 20 and improving the durability of the first coating 30.

[0106] Before the paint is sprayed on the surface of the substrate 20, the surface of the substrate 20 is phosphated to form a second coating 31. This process step can provide stronger bonding force between the first coating 30 and the surface of the substrate 20. Phosphating forms a uniform phosphating film, i.e. the second coating 31, on the surface of the substrate 20. Spraying the paint described in the above embodiment on the surface of the second coating 31, the chemical bonding and physical interlocking between the phosphating film and the paint make the first coating 30 more firmly attached to the outside of the second coating 31. Phosphating not only improves the adhesion of the first coating 30, but also enhances the corrosion resistance and wear resistance of the overall coating.

[0107] The application runs the compressor 10 at high speed under the condition of a small amount of lubricating oil in the compressor 10, respectively uses a conventional crankshaft and a crankshaft 21 provided with a first coating 30 for comparison test, and measures the abrasion amount of the friction pair position of the crankshaft 21. As shown in FIG. 2, the crankshaft 21 includes a long shaft 211 and a short shaft 212, and the abrasion amount of the long shaft 211 and the short shaft 212 is measured respectively. The thickness of the first coating 30 is 10 μm, the crankshaft 21 is not phosphated, the rotation frequency of the compressor 10 is 90 Hz, and the running time of the compressor 10 is 500 h. The crankshaft 21 bears heavy load when the rotation frequency of the compressor 10 is 90 Hz, and in the verification test, the rotation speed of 90 Hz can verify the applicability of the crankshaft 21 in the working environment of the high-speed compressor 10. The specific comparison test data is shown in Table 1 as follows.

[0108] The crankshafts 1 to 3 are crankshafts provided with the first coating 30, and the data difference between the crankshafts 1 to 3 is test error. The surface of the crankshaft is also provided with a second coating, and the second coating and the first coating are sequentially arranged on the surface of the crankshaft. The thickness of the second coating is 3 μm, and the second coating is formed by phosphating process; the thickness of the first coating is 8 μm, and the first coating is formed by spraying the coating material including 25% concentration of graphite, 8% concentration of carbon fiber, 7% concentration of organic resin nanoparticles and 60% concentration of N-methyl-2-pyrrolidone, and the first coating includes graphite, carbon fiber and organic resin nanoparticles. The crankshafts 4 to 6 are conventional crankshafts, and the data difference between the crankshafts 4 to 6 is test error. According to the test data in Table 1, after multiple tests, the abrasion amount of the crankshaft 21 provided with the first coating 30 at the long shaft 211 and the short shaft 212 positions is less than that of the conventional crankshaft. It can be seen from the result that the first coating 30 formed on the surface of the substrate 20 by the coating material provided by the disclosed embodiment has good wear resistance and can improve the wear resistance of the crankshaft 21 in the high-speed compressor 10.

[0109] Table 1

[0110] The above description and drawings are illustrative of embodiments of the present disclosure and are not intended to be limiting. Other embodiments can include structural and other changes. Embodiments are merely representative of possible variations. Individual components and functions are optional unless explicitly required, and the order of operations can be varied. Portions and features of some embodiments can be included in, or substituted for, those of other embodiments. Embodiments of the present disclosure are not limited to the structures described above and shown in the drawings, and can be varied in many ways. The scope of the present disclosure is limited only by the claims that follow. Also, the language used in the specification is for the purpose of describing embodiments and is not intended to limit the claims. As used throughout the specification and claims, the singular forms "a," "an," and "the" include plural references unless the context clearly dictates otherwise. Similarly, the term "and / or" as used herein refers to any and all possible combinations of one or more of the associated listed items. Additionally, the term "comprises" and variations thereof, when used in this application, do not exclude the presence of one or more additional features, integers, steps, operations, elements, and / or groups thereof. The term "comprises" when used in this application does not exclude the presence of other than those features, integers, steps, operations, elements, and / or groups thereof. Where the phrase "one or more" appears herein, what is also meant is "at least one." Where the phrase "one or more of, followed by a listing of items, appears herein, what is also meant is "at least one of the listed items."

Claims

1. A coating material for a compressor, comprising: graphite, carbon fiber, and nanoparticles.

2. The coating material of claim 1, wherein, the nanoparticles are organic resin.

3. The coating material of claim 1 or 2, further comprising: a solvent, the solvent comprising N-methyl-2-pyrrolidone.

4. The coating material of claim 3, wherein, the concentration of graphite ranges from 8% to 30%, the concentration of carbon fiber is less than or equal to 10%, and the concentration of N-methyl-2-pyrrolidone ranges from 30% to 60%; or, the concentration of graphite is 15%, the concentration of carbon fiber is 2%, and the concentration of N-methyl-2-pyrrolidone is 50%; or, the concentration of graphite is 25%, the concentration of carbon fiber is 8%, and the concentration of N-methyl-2-pyrrolidone is 60%; and / or the concentration of nanoparticles ranges from 1% to 15%; or, the concentration of nanoparticles is 7%.

5. A coating layer for a compressor, the coating layer being formed from the coating material of any one of claims 1 to 4.

6. A compressor, comprising: a base body, a surface of the base body being provided with the coating layer of claim 5; wherein the coating layer of claim 5 forms a first coating layer on the surface of the base body.

7. The compressor of claim 6, wherein, the first coating layer has a thickness ranging from 5 μιη to 15 μιη; or, the first coating layer has a thickness of 8 μιη.

8. The compressor of claim 6 or 7, wherein, the surface of the base body is further provided with a second coating layer, the second coating layer being disposed between the surface of the base body and the first coating layer.

9. The compressor of claim 8, wherein, the second coating layer is formed by a phosphating process; and / or the second coating layer has a thickness of 2 μιη to 5 μιη, or the second coating layer has a thickness of 3 μιη.

10. The compressor of any one of claims 6 to 9, wherein, the base body comprises one or more of a crankshaft, a piston, and a cylinder; and / or the base body is made of a spheroidal graphite cast iron material or a steel material.

11. A crankshaft for a compressor, a surface of the crankshaft being provided with a first coating layer formed from the coating material of any one of claims 1 to 5, the first coating layer having a friction coefficient that is less than a friction coefficient of the crankshaft.

12. A method for forming a coating layer on a surface of a base body, the method comprising the steps of: spraying the coating material of any one of claims 1 to 5 on the surface of the base body; placing the base body in an incubator to volatilize a solvent; and placing the base body in a high-temperature oven to cure the coating material.

13. The method of claim 12, wherein, the temperature of the incubator is set to 80 °C, and the base body is placed in the incubator for 30 minutes; and / or the temperature of the high-temperature oven is set to 210 °C, and the base body is placed in the high-temperature oven for 1 hour.

14. The method of claim 12 or 13, further comprising, before the step of spraying the coating material on the surface of the base body: subjecting the surface of the base body to a sandblasting process or a phosphating process.

Images