Swash Plate Dual Resin Coating for Wear Resistance
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Solution Overview
Problem
Clutchless swash plate type compressors face poor lubrication conditions leading to increased frictional heat, wear, and seizure due to insufficient lubricating oil circulation, which affects the sliding surfaces between the swash plate and the shoe, especially when the coolant washes away the lubricating oil.
Innovation Solution
A swash plate with a substrate coated by a hard first resin layer and a soft second resin layer, featuring an annular groove and minute irregularities, where the second resin layer is the initial sliding surface that wears to expose the hard first resin layer for improved wear resistance and fit with the shoe.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single resin layer is used on the swash plate sliding surface, then manufacturing is simpler, but wear resistance is insufficient under poor lubrication conditions
Solution Approach 1:
The sliding surface coating is segmented into two distinct resin layers: a hard resin layer (5-20 μm thick) providing wear resistance and a soft resin layer (2-10 μm thick) providing conformability and lubrication retention. This segmentation allows each layer to perform its specific function optimally, with the hard layer resisting wear under poor lubrication and the soft layer maintaining contact with the shoe surface.
Solution Approach 2:
The patent applies composite materials by combining hard resin and soft resin in a layered structure. The hard resin provides mechanical strength and wear resistance, while the soft resin provides conformability and lubrication retention. This composite structure resolves the contradiction by integrating materials with complementary properties to achieve both durability and adaptability.
2Reliability
If a metal sliding surface is used, then wear resistance is high, but seizure occurs easily under poor lubrication conditions
Solution Approach 1:
The soft resin layer acts as an intermediary between the hard resin layer and the metal shoe sliding surface. It provides a compliant interface that retains lubrication and reduces direct metal-to-metal contact, preventing seizure while allowing the hard resin layer to provide the necessary friction resistance for wear protection.
Solution Approach 2:
The patent changes the surface hardness parameter by using a soft resin layer on the outer surface instead of hard metal. This soft layer has lower hardness but higher conformability and lubrication retention, preventing seizure under poor lubrication conditions while the underlying hard resin layer maintains friction resistance.
3Force
If the sliding surface is made smoother, then initial friction is reduced, but lubrication retention decreases under poor lubrication conditions
Solution Approach 1:
The sliding surface has non-uniform local quality with minute irregularities (micro-roughness) distributed across the soft resin layer surface. These local irregularities create micro-reservoirs that trap and retain lubrication, while the overall surface remains sufficiently smooth to maintain low friction during sliding operations.
Data Source
Figure 1~2
Figure 3~4
AI summary
A swash plate 3 includes an substrate 11 made of an iron-based material, a hard first resin layer 12 provided to coat an end surface of the substrate 11, and a soft second resin layer 13 provided to coat the first resin layer 12. A spiral annular groove 12A is formed in a surface of the first resin layer 12, and the second resin layer 13 is provided to match a sectional shape of the first resin layer 12. With the soft second resin layer 13 on a sliding surface 3A of the swash plate 3, the swash plate 3 having a good fit in an initial stage of sliding can be provided. When the second resin layer 13 partially wears, a protrusion 12 of the first resin layer 12 of hard resin is exposed, and thus the swash plate 3 having good wear resistance can be provided. The swash plate 3 having good sliding properties can be provided.