Refrigerant Compressor Sliding Coating for Delamination Resistance

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Solution Overview

Problem

Conventional refrigerant compressors face high manufacturing costs and reduced yield due to the sequential formation of nitride, intermediate, and amorphous carbon layers, which can lead to delamination and surface roughness issues, and require separate processing furnaces and programs, while also experiencing reduced adhesiveness and increased surface roughness from nitridation treatments.

Innovation Solution

A refrigerant compressor with a sliding member formed of tool steel, featuring sequentially deposited layers: a chromium layer, a chromium-tungsten carbide alloy layer, a metal-containing amorphous carbon layer with tungsten or tungsten carbide, and an amorphous carbon layer containing carbon and hydrogen, without the need for a nitride layer, reducing hardness differences and processing complexity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a nitride layer, intermediate layer, and amorphous carbon layer are sequentially formed on the vane surface using separate processes, then the amorphous carbon layer adhesiveness is improved, but the manufacturing cost increases and processing complexity increases

Engineering Contradiction:

Improveamorphous carbon layer adhesivenessVSAvoidprocessing complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent combines the nitride layer formation and amorphous carbon layer formation into a single continuous processing step using a dual-purpose coating device. The nitride layer is formed first, then the amorphous carbon layer is deposited directly over it without removing the nitrogenous compound layer, eliminating the need for separate processing furnaces and programs while maintaining layer adhesiveness.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The coating device is designed to perform multiple functions: it can form both the nitride layer and the amorphous carbon layer in sequence using the same equipment. This multi-functional approach replaces the conventional requirement for separate processing furnaces, reducing device complexity while achieving the same protective effect.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Strength

If a nitride layer is formed on the vane surface through nitriding treatment, then the base material hardness is improved, but the surface roughness deteriorates and adhesiveness of subsequent layers is reduced

Engineering Contradiction:

Improvebase material hardnessVSAvoidsurface roughness

Core Design Contradiction:

StrengthVSManufacturing precision

Solution Approach 1:

The patent converts the harmful effect of the nitrogenous compound layer (which reduces adhesiveness and increases surface roughness) into a beneficial intermediate structure. Instead of removing it, the amorphous carbon layer is deposited directly over the nitrogenous compound layer, utilizing it as a transition layer that maintains both the hardness benefits of nitriding and the adhesiveness needed for the carbon layer.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

3Manufacturing precision

If separate processing furnaces and programs are used to form nitride layer, intermediate layer, and amorphous carbon layer, then each layer can be optimized, but the manufacturing cost increases

Engineering Contradiction:

Improvelayer formation qualityVSAvoidmanufacturing cost

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The patent merges the formation of the nitride layer and amorphous carbon layer into a single continuous process using one coating device. This eliminates the need for multiple furnaces and separate processing programs, reducing manufacturing costs while maintaining the quality optimization of each layer through controlled deposition parameters.

Inventive Principle:

Principle #5Merging (Combining)

4Reliability

If the nitrogenous compound layer is removed from the nitride layer surface, then adhesiveness is improved, but component accuracy is difficult to maintain and yield rate decreases

Engineering Contradiction:

Improvelayer adhesivenessVSAvoidcomponent accuracy

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

Instead of removing the nitrogenous compound layer to improve adhesiveness (conventional approach), the patent inverts the approach by depositing the amorphous carbon layer directly over the nitrogenous compound layer. This eliminates the need for removal processes that compromise component accuracy while achieving the desired adhesiveness through the carbon layer's inherent bonding properties.

Inventive Principle:

Principle #13The other way round (Inversion)

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 configuration enhances adhesiveness and prevents delamination of the amorphous carbon layer, improves surface roughness, and reduces manufacturing costs by eliminating the need for separate processing steps and nitridation treatments, resulting in a high-abrasion-resistant and cost-effective refrigerant compressor.

Implementation Method 1

A first layer composed of a single layer of chromium, a second layer composed of an alloy layer of chromium and tungsten carbide, a third layer composed of a metal-containing amorphous carbon layer containing at least one of tungsten and tungsten carbide, and a fourth layer composed of an amorphous carbon layer containing carbon and hydrogen without metals are sequentially formed on a surface of the sliding member

Methodology Applied

Scientific EffectPhysical Vapour Deposition: Physical Vapour Deposition

Implementation Method 2

Methodology Applied

Scientific EffectChemical Vapour Deposition: Chemical Vapour Deposition

Data Source

PatentUS8585385B2Refrigerant compressor and refrigerating cycle device

Publication Date: 2013.11.19 TOSHIBA CARRIER CORP

AI summary

A refrigerant compressor includes a first layer (24) composed of a single layer of chromium, a second layer (25) composed of an alloy layer of chromium and tungsten carbide, a third layer (26) composed of an amorphous carbon layer containing at least one of tungsten and tungsten carbide, and a fourth layer (27) composed of an amorphous carbon layer containing carbon and hydrogen without metals, which are sequentially formed on a surface of a sliding member (13b) of a compression mechanism formed of tool steel. The second layer (25) is formed to have a chromium content higher on a side of the first layer (24) than a side of the third layer (26), and have a tungsten carbide content higher on the side of the third layer (26) than the side of the first layer (24). In addition, the third layer (26) is formed to have a tungsten content or a tungsten carbide content higher on a side of the second layer (25) than a side of the fourth layer (27).