Zinc Phosphate Film on Swash Plate Compressor Piston
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Solution Overview
Problem
The formation of solid lubricant films, such as those made of tin, is costly and does not adequately address the issue of seizing at sliding contact portions between the piston and shoe in swash plate compressors, necessitating a cost-effective solution for galling and seizing resistance.
Innovation Solution
A zinc phosphate film is formed on the piston at sliding contact areas with the shoes, providing galling and seizing resistance while reducing costs compared to conventional solid lubricant films.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a solid lubricant film such as tin is formed on the piston sliding surface, then galling resistance and seizing resistance are improved, but manufacturing cost increases
Solution Approach 1:
The patent changes the material parameter of the lubricant film from solid lubricant (tin) to chemical conversion film (zinc phosphate). This parameter change maintains adequate galling and seizing resistance while significantly reducing manufacturing cost, as zinc phosphate film can be applied through conventional phosphating processes rather than expensive solid lubricant deposition methods
Solution Approach 2:
The patent employs a cost-effective zinc phosphate film instead of expensive solid lubricant tin coating. The zinc phosphate film provides sufficient protective function at lower material and processing costs, making it an economically viable alternative for sliding surface protection in swash plate compressors
2Reliability
If conventional solid lubricant films are used, then seizing resistance is improved, but the solution is costly and does not adequately prevent seizing
Solution Approach 1:
The patent creates a composite protective system by forming a zinc phosphate film on the piston sliding surface and combining it with lubricant retention features. This composite approach provides adequate seizing resistance through the chemical film's boundary lubrication properties, achieving reliable protection at lower cost compared to solid lubricant tin coatings
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 zinc phosphate film effectively reduces galling and seizing at sliding contact points, even in unlubricated conditions, and is more cost-effective to produce than traditional solid lubricant films, enhancing the operational reliability and efficiency of swash plate compressors.
Implementation Method 1
a zinc phosphate film is formed on each portion of the piston at which each of the pair of shoes is in sliding contact... running-in ability of the zinc phosphate film can reduce occurrence of galling or seizing at the sliding contact portions
Data Source
AI summary
A swash plate compressor 100 includes a swash plate 111 that rotates with a drive shaft 110, a pair of shoes 137a and 137b placed to sandwich a portion of the swash plate 111 close to a periphery of the swash plate 111, and a piston 136 connected to the swash plate 111 via the pair of shoes 137a and 137b. The piston 136 reciprocates in a cylinder bore 101a as the swash plate 111 rotates due to the rotation of the drive shaft 110. In the swash plate compressor 100, a zinc phosphate film is formed on each portion of the piston 136 at which the corresponding shoe 137a, 137b is in sliding contact. This reduces occurrence of galling or seizing at the sliding contact portions between the piston 136 and the shoes 137a and 137b.