Self-lubricating Swash Plate Coating for CO2 Refrigerant Systems
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Solution Overview
Problem
Existing swash plates for automobile air conditioners face challenges with poor self-lubricating properties, complex and costly production processes, and the use of lead-containing materials, especially under severe sliding friction conditions due to the transition from Freon to carbon dioxide refrigerants.
Innovation Solution
A self-lubricating wearable coating for swash plates composed of polyphthalazinone ether sulfone (PPES), polyphthalazinone ether ketone (PPEK), and polyphthalazinone ether sulfoneketone (PPESK) combined with fluoroplastic and inorganic materials, applied using a simple and low-cost process, eliminating lead and enhancing abrasion and thermal resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If copper-lead-aluminium-silicon plating is used to achieve anti-friction and anti-seizure properties, then the swash plate gains self-lubricating capability, but the material contains lead which is harmful to human body and environment
Solution Approach 1:
The invention extracts and removes lead from the plating material composition, replacing it with alternative materials (copper, aluminium, silicon, and carbon fiber) that provide the same self-lubricating and anti-friction properties without the harmful environmental and health effects of lead
Solution Approach 2:
The invention uses a composite plating material consisting of copper, aluminium, silicon, and carbon fiber in specific proportions. This composite material achieves the desired self-lubricating and anti-seizure properties through the synergistic effect of its components, particularly carbon fiber which provides excellent lubrication without containing lead
2Reliability
If Ni60+20%WC thermal spraying or zinc-aluminium alloy thermal spraying/sintering is used to achieve anti-friction and anti-seizure properties, then the swash plate gains wear resistance, but the production process becomes complicated and cost increases
Solution Approach 1:
The invention adopts a more economical plating process that achieves the required wear resistance without the complexity and high cost of thermal spraying or sintering technologies. The electroplating or electrodeposition method used is simpler, more cost-effective, and equally effective in providing wear-resistant and self-lubricating surfaces
Solution Approach 2:
The invention changes the material composition parameters to include carbon fiber and optimizes the plating process parameters to achieve the desired performance. By adjusting the composition ratios and processing conditions, the patent achieves wear resistance comparable to or better than thermal spraying methods while using a simpler and less costly process
3Object-affected harmful factors
If carbon dioxide is used as refrigerant instead of Freon to protect the ozonosphere, then environmental protection is improved, but the load on the swash plate increases making sliding friction conditions more severe
Solution Approach 1:
The invention uses composite plating materials containing carbon fiber, copper, aluminium, and silicon that provide enhanced self-lubricating properties and load-bearing capacity. The carbon fiber component specifically addresses the increased friction and wear conditions caused by higher loads from carbon dioxide refrigerant systems
Solution Approach 2:
The plating material is designed to provide self-lubricating properties that enable the swash plate to operate under severe friction conditions without external lubrication. The material structure allows it to self-regulate friction and wear, maintaining performance even under the increased loads from carbon dioxide refrigerant systems
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 coating provides superior self-lubricating and abrasion-resistant properties, is lead-free, and reduces production costs, with improved performance under severe sliding friction conditions, extending the swash plate's lifespan and maintaining low abrasion loss and seizure resistance.
Implementation Method 1
The coating provides superior self-lubricating and abrasion-resistant properties
Implementation Method 2
The coating provides superior self-lubricating and abrasion-resistant properties
Implementation Method 3
enhancing abrasion and thermal resistance
Data Source
Figure 1
Figure 2
AI summary
A self-lubricating wearable coating swash plate which is consisted of a metallic substrate (6) and a self-lubricating wearable coating (5) formed thereon. The main constituents of the coating (5) include polymer material, fluoroplastic, solid lubricant and wearable inorganics. The process for producing the swash plate includes, the polymer material is dissolved by solvent firstly, then the fluoroplastic, solid lubricant and wearable inorganics are added, a coating material is prepared by stirring and dispersion. The swash plate has good self-lubricating and abrasion resistant properties, and can be produced by simple process at low costs.