Plastic Compressor Shoes for Lubrication and Cost Reduction
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Solution Overview
Problem
Conventional swash plate compressors face challenges in maintaining sufficient lubrication between the swash plate and shoes, with existing methods like tin plating or molybdenum disulfide coatings being costly and complex to apply.
Innovation Solution
The use of plastic bearings with a hemispherical surface and planar base, made from materials like polyamide imide with additives such as PTFE and carbon fiber, which can trap lubricants to enhance lubricity and durability, reducing the need for expensive coatings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If tin plating or molybdenum disulfide coatings are applied to the swash plate, then lubrication between the swash plate and shoes is improved, but manufacturing cost and process complexity increase
Solution Approach 1:
The patent replaces expensive, complex plating processes with a simpler, more cost-effective plastic shoe material that achieves adequate lubrication without requiring expensive tin or molybdenum disulfide coatings on the swash plate. The plastic shoes themselves provide the lubricating function through their material composition rather than requiring plated surfaces.
Solution Approach 2:
The patent employs plastic materials with lubricant additives (such as PTFE, graphite, or molybdenum disulfide embedded in the plastic matrix) to create a composite material that provides both structural function and lubrication. This eliminates the need for separate plating layers while maintaining or improving lubrication performance.
2Reliability
If thermally-applied solid lubricant coatings are used, then lubrication is improved, but manufacturing cost increases
Solution Approach 1:
The patent eliminates expensive thermal spray processes by incorporating lubricant functionality directly into the plastic shoe material through additives. This approach is significantly more cost-effective than applying thermal coatings while achieving the same lubrication objective.
Solution Approach 2:
The patent changes the approach from applying external coatings to modifying the base material properties by incorporating lubricant additives into the plastic composition. This parameter change transforms the lubrication mechanism from surface coating to bulk material property, simplifying manufacturing.
3Ease of manufacture
If plastic bearing material is used instead of metal shoes, then manufacturing cost decreases and lubrication is maintained, but load-bearing capacity may be reduced
Solution Approach 1:
The patent uses composite plastic materials that combine structural plastic base materials with embedded lubricant additives and potentially reinforcing fillers. This composite structure provides both the load-bearing capability of a rigid material and the lubrication properties needed for low-friction operation, overcoming the weakness of pure plastics.
Solution Approach 2:
The patent modifies the physical and chemical parameters of the plastic material through additive incorporation, transforming it from a simple polymer into a functional composite with enhanced mechanical properties and lubrication characteristics suitable for bearing applications.
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 solution provides a cost-effective and efficient method to maintain lubricity between the swash plate and shoes, improving the operability and durability of compressors while simplifying the manufacturing process.
Implementation Method 1
polyamide imide with additives such as PTFE and carbon fiber, which can trap lubricants to enhance lubricity
Data Source
AI summary
Embodiments of the present invention are disclosed herein. One embodiment of a bearing for a piston engine has a bearing made of a plastic material and having a substantially planar base and a substantially hemispherical portion. The base is configured to engage with a swash plate, and the hemispherical portion is configured to engage with a piston.