Compressor Moving Part with DLC Coating and Etched Microgrooves
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Solution Overview
Problem
Compressors face durability issues due to repetitive contact friction, leading to wear and energy loss, which existing technologies have not adequately addressed.
Innovation Solution
A moving part for compressors is designed with a polished steel base material, an etching-processed area featuring microgrooves, an adhesive layer, and a diamond-like carbon coating layer, which includes silicon to reduce friction and enhance durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a moving part is made of steel material with polished surface, then hardness and strength are improved, but friction and wear increase due to contact with other parts
Solution Approach 1:
The patent applies composite materials by combining steel base material with diamond-like carbon coating layer. The steel provides structural strength and hardness, while the diamond-like carbon coating provides low friction and wear resistance. This composite structure resolves the contradiction by integrating materials with complementary properties.
Solution Approach 2:
The patent changes the surface parameters of the steel material by applying a diamond-like carbon coating layer. This coating alters the surface friction coefficient and wear characteristics without changing the bulk mechanical properties of the steel, thereby reducing friction while maintaining hardness.
2Object-affected harmful factors
If a coating layer is applied on the polished surface, then friction and wear are reduced, but bonding strength between coating and base material may be insufficient
Solution Approach 1:
The patent applies preliminary action by performing surface treatment (polishing and etching) on the steel base material before applying the diamond-like carbon coating. This preliminary surface preparation creates microgrooves and enhances surface energy, ensuring strong adhesion between the coating layer and base material, thereby preventing coating delamination during operation.
Solution Approach 2:
The patent uses an adhesive layer as an intermediary between the steel base material and the diamond-like carbon coating layer. This intermediate layer enhances the bonding strength and ensures reliable attachment of the coating to the substrate, resolving the contradiction between wear resistance and bonding strength.
3Reliability
If etching process is performed to create microgrooves, then adhesion of coating layer is improved, but manufacturing complexity increases
Solution Approach 1:
The patent applies parameter changes by modifying the surface morphology through etching to create microgrooves. This surface parameter change enhances the mechanical interlocking and adhesion of the coating layer without requiring complex manufacturing processes or additional components.
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 solution provides a moving part with low friction coefficients, improved wear resistance, and increased hardness, effectively reducing wear and enhancing the compressor's durability and operational stability.
Implementation Method 1
an adhesive layer arranged between the base material and the coating layer and bonding the coating layer to the base material
Implementation Method 2
an etching-processed area having a plurality of microgrooves extending in a downward direction into the base material from the polished surface
Implementation Method 3
A contact area between the moving part and other parts may require high hardness and low friction characteristics
Data Source
AI summary
A moving part of a compressor, a compressor including the moving part, and a method of manufacturing the moving part, the moving part including a base material having a polished surface and including a steel material; an adhesive layer arranged on the polished surface; and a coating layer including diamond-like carbon. The adhesive layer may be arranged between the base material and the coating layer and bond the coating layer to the base material, and the base material may include an etching-processed area having a plurality of microgrooves (MG) extending in a downward direction into the base material from the polished surface.