CN101094731B - 内燃机的连杆以及对其滑动轴承面进行涂覆的方法 - Google Patents

内燃机的连杆以及对其滑动轴承面进行涂覆的方法 Download PDF

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CN101094731B
CN101094731B CN200580042413.5A CN200580042413A CN101094731B CN 101094731 B CN101094731 B CN 101094731B CN 200580042413 A CN200580042413 A CN 200580042413A CN 101094731 B CN101094731 B CN 101094731B
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库尔特·迈尔
赖因哈德·罗丝
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Abstract

本发明涉及一种用于内燃机的连杆，该连杆具有：带有滑动轴承面的连杆小头孔，该连杆小头孔用于容纳活塞销；带有滑动轴承面的连杆大头孔，该连杆大头孔包围连杆轴颈。为了高效和低成本地避免活塞销和连杆轴颈的卡死和磨损，由其中包含有固体润滑剂颗粒的热固性树脂构成的自润滑涂层通过旋转喷涂直接涂在至少一个滑动轴承面上。

Description

内燃机的连杆以及对其滑动轴承面进行涂覆的方法
技术领域
本发明涉及一种用于内燃机的连杆，该连杆具有：一个带有滑动轴承面的连杆小头孔，该连杆小头孔用于容纳活塞销；一个带有滑动轴承面的连杆大头孔，该连杆大头孔包围连杆轴颈，本发明还涉及一种用于对滑动轴承面进行涂覆的方法。
背景技术
具有直接涂层的连杆头孔的连杆在现有技术中，例如在DE 19731 625以及EP 0 863 322 B1中被公开。其中公开了通过取消连杆轴瓦简化连杆轴承的装配。为此，由金属、特别是由铝青铜构成的轴承层通过等离子喷射直接涂在连杆大头孔上，该轴承层为轴承位置提供足够的润滑。然而，为了保持用于连杆装配的尺寸精确度以及涂层的表面质量，始终都要例如通过研磨或者精密车削对金属层进行必要的机械后处理，而该机械后处理导致不能明显降低该种类型连杆的生产费用。此外，在实践中可以看到，由于在轴承中的磨损，该金属层并不能提供足够的防卡死可靠性和润滑可靠性，从而使该设计方案中的连杆轴承的使用寿命受到限制。
DE 102 032 850 C1公开了一种可烧结的粉末混合物，其由一种铝基粉末和/或其合金或者一组金属(如铜、锡、锂或者锰)构成，该粉末混合物被压制成生坯，接下来该生坯被再次压实和烧结，其中烧结层也可以涂在由钢或者铸件构成的部件上。然而，由此并没有实现改善的滑动特性，而仅仅降低了部件的重量。
同样，无轴瓦连杆例如在DE 101 29 559 C1中公开，其具有连杆小头孔的直接涂层，该涂层由铅青铜构成，并作为润滑层。然而，这里同样产生前述缺点，这是因为同样使用金属层作为润滑层。为此，涂层的再加工在尺寸一致性方面需要很大的费用，以便确保在连杆和活塞销之间具有产生最小噪音的狭窄间隙时的装配。
为了改善部件的摩擦特性或者耐摩性，在DE 39 39 704 A1中公开了一种层材料，该材料在喷涂之后在部件的表面生成一种不同厚度的不规则的斑点状的分布。在此，具有较高厚度的区域优选地通过填料颗粒构成，这些填料颗粒混合在层材料中。然而，其缺点是，用于干燥的烘烤过程产生不可控制的不规则的层厚度的降低，由此不能确保精确轴承间隙调整(例如内燃机的滑动轴承、轴瓦或者连杆)。
发明内容
因此，本发明的目的是提出一种用于内燃机的滑动部件，特别是连杆，以及提出一种用于对该滑动部件的滑动轴承面进行涂覆的方法，即使在最狭窄的装配间隙时，利用该滑动部件也可以高效和廉价地实现长期的防卡死保护和防磨损保护。
根据本发明，该目的由一种用于内燃机的连杆来实现，其特征在于，至少一个滑动轴承面具有直接与连杆材料连接的自润滑涂层，所述自润滑涂层由其中包含有固体润滑剂颗粒的热固性树脂构成，以及还通过一种对用于内燃机连杆的连杆头孔的滑动轴承面进行涂覆的方法来实现，其特征在于，由其中包含有固体润滑剂颗粒的热固性树脂构成的自润滑涂层通过旋转喷涂直接涂在至少一个所述滑动轴承面上。
通过将设计为润滑漆的自润滑层(该润滑层由其中包含有固体润滑剂颗粒的热固性树脂构成)直接涂在连杆的连杆头孔的滑动轴承面上，基本实现了下列优点：
不需要为了达到足够的润滑可靠性和防卡死可靠性而配备轴瓦；
不需要为了改善润滑漆的粘附性而在滑动轴承面上涂粘附层；
不需要为了实现预期的尺寸一致性(如涂层的层厚度、最窄的层厚度容差、轴承间隙的调整等等)，以及预期的表面质量(如粗糙度、波度等等)而对所涂润滑漆的表面进行再加工；
相对于已知的金属合金涂层，通过改善的润滑特性获得改善的持久性，进而使连杆轴承获得更长的使用寿命。
根据需要，混入的固体润滑剂颗粒可以分别由下述材料中的一种或两种的混合物构成，所述材料包括石墨、二硫化钼、二硫化钨、六方氮化硼或者聚四氟乙烯，其中，滑动轴承面的硬化的涂层包含50到60重量百分比的固体润滑剂颗粒，从而确保连杆轴承的理想的润滑效果。为此，固体润滑剂颗粒在硬化的润滑漆的层厚度为10-15μm时具有1到3μm的颗粒尺寸。同时层厚度的容差最大为±1μm，由此可以实现最狭窄的装配间隙。
根据本发明的方法，润滑漆有利地通过旋转喷涂的方法涂在连杆头孔的滑动轴承面上，由此，也可以实现对具有较小的直径的连杆头孔进行涂。
如前所述，这样产生的涂层具有几乎恒定的层厚度以及非常好的表面质量。同样，可以很好地限定待涂的区域的深度。相对于通常的涂覆类型，该涂覆方法非常的经济。
附图说明
接下来借助附图对本发明的实施例详细地说明。图中：
图1是根据本发明的被涂的连杆的视图；
图2是沿着图1的线I-I的截面；
图3是根据图2的已经涂覆的连杆的另一个实施例；
图4是用于在连杆的滑动轴承面上涂涂层的装置。
具体实施方式
在图1中示出的、由钢构成的连杆1具有：带有滑动轴承面4的连杆小头孔2、连杆体8、和带有滑动轴承面5的连杆大头孔3。滑动轴承面4和5中示出了自润滑涂层9，该自润滑涂层9由其中包含有固体润滑剂颗粒的热固性树脂(被称为润滑漆)构成。树脂是聚酰胺酰亚胺，并且固体润滑剂颗粒分别由下述材料中的一种或两种的混合物构成，所述材料包括石墨、二硫化钼、二硫化钨、六方氮化硼(h-BN)或者聚四氟乙烯(PTFE)。
为了在连杆头孔的滑动轴承面4和5上涂根据本发明的涂层，用装置10进行旋转喷涂。装置10具有基体11，该基体过渡到旋转喷嘴体13，该喷嘴体具有轴承12、喷嘴14以及喷嘴出口15。驱动装置23用于旋转喷嘴体13。基体11分别具有输送管道17和18，这些管道分别用于润滑漆和压缩空气，并且这些管道在用于计量和混合的混合室19中终止。与混合室19连接的喷射管道20垂直地通到挡板16，该挡板被设置为形成与喷嘴体13间隔开的宽度为0.5mm的环形缝隙，该缝隙用于喷出润滑漆-喷射流24。
具有喷嘴14的喷嘴体13利用驱动装置23在每分钟14000至18000转的转速范围内旋转，从而使润滑漆-压缩空气-混合物通过在环形缝隙的出口上形成的离心力加速，并且作为碟形的喷射流24径向地喷出。在此，这样地选择喷嘴直径D，即该直径大约为待涂连杆头孔直径的一半。
装置在待涂的连杆头孔中插入的深度最多可达喷嘴深度T。因为在轴向方向上的喷射流是狭窄的，所以在轴向上可以通过简单地打开和关闭漆的输送来严格限制待涂面。喷嘴的直径在5mm和25mm之间，并且具有高达50mm的喷嘴深度，从而可利用该装置涂覆用于几乎所有发动机类型的连杆的连杆大头孔和连杆小头孔。
实施例1：
在连杆小头孔中的涂层：
连杆1通过已知的方式机加工制造。连杆小头孔2以Rz(平均峰谷高度)＜6.3μm的表面粗糙度精确地开孔。同时，选择涂覆之前的开孔直径，使得活塞销获得30-40μm的直径间隙。连杆小头孔可以获得球形的成型开孔。之后，连杆被清洗，从而完全去除碎屑、颗粒、加工油(机油)以及类似物质。
为了准备进行涂覆，在连杆头孔的两侧安装遮盖板21，这些遮盖板与连杆小头孔的外部轮廓相匹配。遮盖板21可防止涂到连杆的外侧。
由抗高温性能较好的基体树脂聚酰胺酰亚胺构成的润滑漆包含作为固体润滑剂材料的混合物，该混合物由具有1-3μm的颗粒尺寸的石墨、二硫化钼构成。润滑漆的黏度这样地调节，即不形成滴状，但是具有足够的涂覆性。
喷嘴以每秒10-20mm的进给速度居中插入到连杆头孔中，从而使润滑漆涂在预先加热到50到80℃的连杆上。在已经硬化的状态下，润滑漆包含50-60重量百分比的固体润滑剂。随后，停止输送润滑漆，退出喷嘴。整个涂覆过程在小于5秒的时间内实现。
之后，层在炉中热固化，其中连杆必须在200℃的温度保持10到20分钟。这样获得的层具有大约10μm的厚度，其中层厚度的容差为±1μm。尽管由于层收缩而降低了润滑层的厚度，但是还是实现了窄的径向活塞销间隙，该间隙为10-20μm。
可以以同样的方式生产通常由两半构成的、可以安装在连杆的连杆头孔中的轴瓦或者轴衬的内部滑动面(即活塞销侧)。
实施例2：
在具有润滑油孔的连杆小头孔中进行涂覆：
连杆1基本上根据实施例1来加工和清洗。仅仅是连杆头孔直径被设计为在涂覆之前具有20-30μm的径向活塞销间隙。
为了准备进行涂覆，在连杆头孔的两侧安装遮盖板21，这些遮盖板与连杆小头孔的外部轮廓相匹配。遮盖板21防止涂到连杆的外侧。
由抗高温性能较好的基体树脂聚酰胺酰亚胺构成的润滑漆包含作为固体润滑剂材料的石墨，该石墨具有1-3μm的颗粒尺寸。润滑漆的黏度这样调节，即不形成滴状，但是可以具有足够的涂覆性。
在连杆小头孔2中居中设置的润滑油孔7中不能加入润滑漆。出于该原因，以及为了使润滑油在连杆头孔和活塞销之间的缝隙中很好地分布，涂层在润滑油孔的区域中空出一个径向环绕的“润滑槽”，对应于根据图3的附图。同样可以通过使用相应的掩蔽物来实现一个或者多个平行于连杆头孔的轴线的润滑槽，或者这些润滑槽的组合。用装置11进行涂覆。
喷嘴14放置在连杆侧面(A)，并且在未输送润滑漆的情况下以深度T1伸入到连杆小头孔2中。之后，润滑漆被涂到区域(C)中。在连杆侧面(B)上的遮盖板21的区域中停止漆的输送，并且在喷嘴中残留的漆被喷射在型板上。随后，在不输送漆的情况下，喷嘴14向回移动到深度T2，并且从那里开始对区域(D)喷涂润滑漆。剩余的润滑漆喷洒在连杆侧面(A)区域的遮盖板21上。润滑漆涂在预先加热到50到80℃的连杆上。
之后，层在炉中热固化，其中连杆必须在200℃的温度中保持10到20分钟。这样获得的层具有大约10μm的厚度，其中层厚度的容差为±1μm。尽管由于层收缩而降低了润滑层的厚度，但是还是实现了狭窄的径向活塞销间隙，该间隙为10-20μm。这种狭窄的间隙对于避免由于活塞销的敲击造成的噪音是特别有利的。尽管间隙很狭窄，但是该涂层可以确保不会出现卡死。此外，该涂层可以混入非常小的硬颗粒，这些颗粒可以到达连杆开孔和活塞销之间的缝隙中。
可以以同样的方式生产通常由两半构成的、可以安装在连杆的连杆头孔中的轴瓦或者轴衬的内部滑动面(即活塞销侧)。
实施例3：
在磷化处理的连杆的连杆小头孔中进行涂覆：
连杆1基本上根据实施例1来加工和清洗。连杆头孔的直径在涂覆之前这样地选择，即活塞销获得30-40μm的径向间隙。
之后，对连杆1的上半部进行磷化处理。可以使用商用的磷化液，也就是法兰克福Fa.Chemetall公司的Gardobond G 4098，作为磷化处理溶液。该磷化处理过程产生大约5μm厚的层，该层由铁-锰-磷酸盐构成。一方面，该层用作喷漆的粘附基础，另一方面，其具有很好的润滑特性和分离特性，并且与润滑漆涂层共同作用，一同避免活塞销卡死在连杆小头孔中。
为了对连杆的上半部进行磷化处理，连杆借助于合适的支架仅仅一半浸入到磷化处理溶液中。
润滑漆的涂覆和硬化相应于实施例1来实现。润滑漆的层厚度在最大层厚度容差为±1μm时同样为10μm。由此，径向活塞销间隙(涂覆之后)为0.1-10μm。尽管间隙很狭窄，但是通过双涂层有效地防止了连杆-活塞销-副卡死。
为了执行涂覆工序，也可使用Kirchheim的Sprimag公司的离心设备S-520。
在本发明的范围内，涂层同样可以应用于具有连杆轴衬的连杆或者轴瓦。也可以利用提出的方法对连杆大头孔进行涂覆。
附图标记
1.连杆
2.连杆小头孔
3.连杆大头孔
4.用于连杆小头孔的滑动轴承面
5.用于连杆大头孔的滑动轴承面
6.涂层
7.润滑油孔
8.连杆体
9.涂层，自润滑的(润滑漆)
10.用于旋转喷涂的装置
11.基体
12.喷嘴体的轴承
13.喷嘴体
14.喷嘴
15.喷嘴出口
16.挡板
17.用于润滑漆的输送管道
18.用于压缩空气的输送管道
19.混合室
20.喷射管道
21.遮盖板
22.间隙
23.驱动装置
24.喷射流
D 喷嘴直径
T 喷嘴深度
Da 喷嘴轴线。

Claims (5)

1.一种用于内燃机的连杆(1)，所述连杆具有：带有滑动轴承面(4)的连杆小头孔(2)，所述连杆小头孔用于容纳活塞销；带有滑动轴承面(5)的连杆大头孔(3)，所述连杆大头孔包围连杆轴颈，
其特征在于，
至少一个滑动轴承面(4，5)具有直接与连杆材料连接的自润滑涂层(9)，所述自润滑涂层由其中包含有固体润滑剂颗粒的热固性聚酰胺酰亚胺树脂构成；并且所述固体润滑剂颗粒分别由下述材料中的一种或两种的混合物构成，所述材料包括石墨、二硫化钼、二硫化钨、六方氮化硼或者聚四氟乙烯。
2.根据权利要求1所述的连杆，其特征在于，所述滑动轴承面的涂层包含50到60重量百分比的固体润滑剂颗粒，其中，所述固体润滑剂颗粒具有1到3μm的颗粒尺寸。
3.根据权利要求1或2所述的连杆，其特征在于，所述涂层的层厚度为10-15μm。
4.根据权利要求3所述的连杆，其特征在于，所述层厚度的容差为±1μm。
5.根据权利要求1至4中任一项所述的连杆，其特征在于，所述连杆小头孔的滑动面被涂覆。
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