Refrigerant Compressor Oxide Coating for Low-Viscosity Oil Wear
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Solution Overview
Problem
Conventional refrigerant compressors face issues with abrasion resistance due to the use of lower viscosity lubricating oil and shorter slide lengths, leading to increased friction coefficients and abnormal abrasion, particularly in regions between the crankshaft and bearing sections, which degrades the phosphate coating film's conformability and reliability.
Innovation Solution
A refrigerant compressor design featuring an oxide coating film on iron-based materials, with a diiron trioxide (Fe2O3) layer near the surface and a silicon-rich layer closer to the base material, enhancing adhesivity and conformability, and reducing sliding losses, even with low viscosity lubricating oil.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If lower viscosity lubricating oil is used to improve efficiency, then energy efficiency is improved, but abrasion resistance of the phosphate coating film deteriorates
Solution Approach 1:
The patent changes the chemical composition parameters of the coating film by specifying precise ratios of Zn, Al, Si, and P elements. This creates a coating with optimized properties that maintains abrasion resistance even when using lower viscosity lubricating oil, thus resolving the contradiction between energy efficiency and reliability
Solution Approach 2:
The patent creates a composite coating film by combining multiple elements (Zn, Al, Si, P) in specific ratios. This composite structure provides both the protective qualities needed for abrasion resistance and the compatibility required for working with lower viscosity lubricating oils, simultaneously achieving energy efficiency and reliability
2Productivity
If slide length is shortened to improve efficiency, then productivity is improved, but conformability of the coating film deteriorates
Solution Approach 1:
The patent modifies the chemical composition parameters of the coating to achieve better conformability on shorter slide surfaces. By adjusting the ratios of Zn (3-15 mass%), Al (5-20 mass%), Si (2-10 mass%), and P (1-5 mass%), the coating adapts better to reduced contact lengths, maintaining reliability while supporting higher productivity
3Reliability
If phosphate coating film is applied to prevent abrasion, then abrasion resistance is improved, but friction coefficient increases due to abnormal abrasion
Solution Approach 1:
The patent changes the chemical composition of the coating by incorporating specific ratios of Zn, Al, Si, and P elements. This optimized composition prevents abnormal abrasion while maintaining low friction characteristics, resolving the contradiction between abrasion resistance and friction reduction
Solution Approach 2:
The patent creates a coating that forms a protective yet sacrificial layer that can wear evenly without causing abnormal abrasion. This controlled wear pattern prevents friction spikes while protecting the underlying metal, balancing abrasion resistance with friction management
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 oxide coating film significantly improves abrasion resistance, maintaining reliability and efficiency by reducing sliding losses and preventing abnormal abrasion, thus enhancing the compressor's performance and longevity.
Implementation Method 1
an oxide coating film provided on a surface of the base material, and the oxide coating film including: a portion containing diiron trioxide (Fe2O3)
Data Source
AI summary
A refrigerant compressor reserves lubricating oil with a viscosity of VG2 to VG100 in a sealed container, and accommodates therein an electric component and a compression component which is driven by the electric component and compresses a refrigerant. The compression component includes at least one slide member comprising a base material 171 made of an iron-based material and an oxide coating film 170 provided on a surface of the base material 171. The oxide coating film 170 includes: a portion containing diiron trioxide (Fe2O3), in a region which is closer to an outermost surface of the oxide coating film; and a silicon containing portion containing silicon (Si) which is more in quantity than silicon (Si) of the base material 171, in a region which is closer to the base material 171.