CN101503995B - 自润滑耐磨涂层斜盘及其生产工艺 - Google Patents

自润滑耐磨涂层斜盘及其生产工艺 Download PDF

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CN101503995B
CN101503995B CN200910095953XA CN200910095953A CN101503995B CN 101503995 B CN101503995 B CN 101503995B CN 200910095953X A CN200910095953X A CN 200910095953XA CN 200910095953 A CN200910095953 A CN 200910095953A CN 101503995 B CN101503995 B CN 101503995B
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self
resistant coating
lubricating wear
swash plate
weight percentage
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CN101503995A (zh
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孙志华
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ZHEJIANG CHANGSHENG SLIDING BEARING CO Ltd
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ZHEJIANG CHANGSHENG SLIDING BEARING CO Ltd
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Priority to CN200910095953XA priority Critical patent/CN101503995B/zh
Publication of CN101503995A publication Critical patent/CN101503995A/zh
Priority to PL10745817T priority patent/PL2402606T3/pl
Priority to PCT/CN2010/070646 priority patent/WO2010097033A1/zh
Priority to EP10745817.6A priority patent/EP2402606B1/en
Priority to ES10745817.6T priority patent/ES2462968T3/es
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    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04B—POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
    • F04B27/00—Multi-cylinder pumps specially adapted for elastic fluids and characterised by number or arrangement of cylinders
    • F04B27/08—Multi-cylinder pumps specially adapted for elastic fluids and characterised by number or arrangement of cylinders having cylinders coaxial with, or parallel or inclined to, main shaft axis
    • F04B27/10—Multi-cylinder pumps specially adapted for elastic fluids and characterised by number or arrangement of cylinders having cylinders coaxial with, or parallel or inclined to, main shaft axis having stationary cylinders
    • F04B27/1036—Component parts, details, e.g. sealings, lubrication
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    • C09D181/00—Coating compositions based on macromolecular compounds obtained by reactions forming in the main chain of the macromolecule a linkage containing sulfur, with or without nitrogen, oxygen, or carbon only; Coating compositions based on polysulfones; Coating compositions based on derivatives of such polymers
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Abstract

本发明所述的自润滑耐磨涂层斜盘，是由金属基体和自润滑耐磨涂层组成，在金属基体两侧环形平面上涂有自润滑耐磨涂层，所述的自润滑耐磨涂层的组成成份包括高分子材料、氟塑料、固体润滑剂及无机物。本发明所述的自润滑耐磨涂层斜盘的生产工艺，其自润滑耐磨涂层是配制成液态涂料涂上去的，液态涂料的配置方法为先用溶剂N-甲基吡咯烷酮或二甲基乙酰胺溶觧高分子材料主材，再添加氟塑料、固体润滑剂和耐磨无机物进行充分的搅拌和分散，制成一定含固量的涂料。本发明的斜盘自润滑和耐磨性能好，生产工艺简单，生产成本低且不含对人体和环境有害的金属铅。

Description

自润滑耐磨涂层斜盘及其生产工艺
技术领域
本发明涉及斜盘式汽车空调压缩机的斜盘和生产工艺。特别涉及用于改善汽车空调压缩机中斜盘和滑履间的润滑和减磨性能的斜盘。与本发明有关的技术领域包括斜盘式压缩机、具有复合组织的斜盘滑动层、高分子自润滑材料等。
背景技术
斜盘式汽车空调压缩机的工作原理是通过倾斜固定于旋转轴上的斜盘的转动，推动压缩机活塞的往复运动，从而实现了制冷剂的吸入、压缩、排出。正是活塞滑履在斜盘上的相对滑动使斜盘的旋转运动转换为活塞的往复运动。
斜盘的滑动有如下特点，就是在压缩机运动的初期，当润滑油尚未到达之前，气态制冷剂就已到达斜盘和滑履的各部位，并冲洗滞留在滑动表面的润滑油。因此，在刚启动压缩机之后，斜盘和滑履是在没有润滑油的干摩擦条件下的相对滑动。
在气态制冷剂开始和润滑油形成油雾进入压缩机的大约一分钟时间内，压缩机斜盘和滑履处于一种无润滑或不充分润滑状态。在如此条件下工作的斜盘必须具有耐磨防咬合和自润滑的特性。
针对上述斜盘的工作特性，业界有多种制作方案，举例如下：
日本大丰工业株式会社(中国专利公开号CN1321220A)的铜铝喷镀斜盘，其技术方案是在斜盘的工作面喷镀一层铜铅铝硅层，来达到减磨防咬合的特性。但其材料中含有较多的铅，而铅是一种对人体有害物质，已被大多数国家禁止使用或严格控制使用量。
上海三电贝尔汽车空调有限公司(中国专利申请号200310109214.4)的Ni60+20％WC合金热喷涂斜盘，其技术方案是在斜盘的工作面热喷涂一层Ni60+20％WC合金层，来达到减磨防咬合的特性。上海三电贝尔汽车空调有限公司(中国专利申请号200710040291.7)的用碳化硅(SiC)颗粒增强的锌铝合金斜盘，其技术方案是在斜盘的工作面热喷涂或烧结一层锌铝合金合金层。上海三电贝尔汽车空调有限公司(中国专利申请号200310108606.9)的耐磨层由聚醚醚酮(PEEK)和润滑性材料混合而成的斜盘，其技术方案是在斜盘的工作面热喷涂或烧结一层镍镉合金中间层，再铺设一层聚醚醚酮(PEEK)和润滑性材料混合而成的材料。日本丰田自动织机株式会社(中国专利公开号CN1401898A)的一种含有固体润滑剂的热塑性聚酰亚胺涂层斜盘，其技术方案是在斜盘的工作面上通过静电喷涂一层包含固体润滑剂的聚酰亚胺(PI)粉末，通过加热融化粉末形成涂层。采用以上这些技术方案在一定程度上能提供斜盘的耐磨防咬合和自润滑的特性，但也都有工艺复杂、成本较高的缺点。
目前为保护大气层的臭氧层，原氟利昂等制冷剂将被替代，二氧化碳作为空调压缩机的制冷剂引起人们的普遍关注，相对于使用氟利昂作为制冷剂的压缩机而言，二氧化碳压缩机通过活塞作用在斜盘上的载荷更大，使得滑动摩擦工况更加恶劣，故更急需一种性能更加优良的自润滑耐磨涂层斜盘。
发明内容
本发明的目的是设计出一种自润滑耐磨涂层斜盘及其生产工艺。以提供一种性能优良的用于斜盘式汽车空调压缩机的斜盘，同时用本发明的工艺降低生产成本。
本发明要解决的是现有斜盘耐磨自润滑性能差、生产工艺复杂、生产成本高、所用的涂层材料含有铅存在污染等的问题。
本发明为解决上述问题而采用的技术方案是：
本发明所述的一种自润滑耐磨涂层斜盘，是由金属基体和自润滑耐磨涂层组成，在金属基体两侧环形平面上涂有自润滑耐磨涂层，该自润滑耐磨涂层构成所述斜盘环形平面工作层；所述的自润滑耐磨涂层的组成成份包括高分子材料、氟塑料、固体润滑剂及无机物。
本发明所述的自润滑耐磨涂层斜盘的生产工艺，所述自润滑耐磨涂层是配制成液态涂料涂上去的，液态涂料的配置方法为：先用溶剂N-甲基吡咯烷酮或二甲基乙酰胺溶觧高分子材料主材，再添加氟塑料、固体润滑剂和耐磨无机物进行充分的搅拌和分散，制成一定含固量的涂料。
本发明的优点：
1，采用杂萘联苯聚醚砜(PPES)、杂萘联苯聚醚酮(PPEK)、杂萘联苯聚醚砜酮(PPESK)材料组成斜盘涂层的主体材料，由于其材料固有的高强度、耐热、耐磨和耐蚀性能，加上氟塑料和固体润滑剂填充的自润滑性和填充耐磨无机物。斜盘的自润滑和耐磨性能超过现有的斜盘。
2，耐磨层中不含有对人体和环境有害的金属铅，符合未来环保及汽车零部件无铅化的发展要求。
3，斜盘的生产工艺简单，成本低。
附图说明
图1为本发明用于斜盘式汽车空调压缩机总体结构示意图。
图2是本发明自润滑耐磨涂层斜盘剖面示意图。
具体实施方式
下面结合附图和实施例，对本发明作进一步详细的说明。
图1为本发明用于斜盘式汽车空调压缩机的结构示意图。斜盘式汽车空调压缩机的工作原理是通过倾斜固定于旋转轴1上的斜盘2的转动，推动压缩机活塞4的往复运动，从而实现了制冷剂的吸入、压缩、排出。正是活塞滑履3在斜盘2上的相对滑动使斜盘2的旋转运动转换为活塞4的往复运动。
下面将结合附图2对本发明作详细的介绍：本发明的自润滑耐磨涂层斜盘，是由金属基体6(金属体)和自润滑耐磨涂层5组成。所述金属基体6的材料为金属基体为铁基或铁基合金、铜基或铜基合金、铝基或铝基合金、锌基或锌基合金；所述金属基体6是通过机械加工方式制成的，经过机械加工成斜盘金属基体6。自润滑耐磨涂层5是通过刷涂或喷涂等方式结合在斜盘金属基体6两侧的环形平面上形成自润滑耐磨涂层斜盘。该自润滑耐磨涂层5构成所述斜盘环形平面工作层。
所述的自润滑耐磨涂层5组成成份包括：高分子材料、氟塑料、固体润滑剂及无机物。
高分子材料选用杂萘联苯聚醚砜(PPES)、杂萘联苯聚醚酮(PPEK)、杂萘联苯聚醚砜酮(PPESK)三种材料中的一至三种；在自润滑耐磨涂层5中杂萘联苯聚醚砜(PPES)重量百分含量控制在0～55％、杂萘联苯聚醚酮(PPEK)重量百分含量控制在0～40％、杂萘联苯聚醚砜酮(PPESK)重量百分含量控制在0～15％。
氟塑料选用聚四氟乙烯(PTFE)、全氟乙烯丙烯四氟乙烯六氟丙烯(FEP)、四氟乙烯全氟烷氧基乙烯基醚共聚物(PFA)、聚偏氟乙烯(PVDF)、乙烯四氟乙烯共聚物(ETFE)和乙烯-三氟氯乙烯共聚物(EDTFE)材料中的至少一种；在自润滑耐磨涂层5中聚四氟乙烯(PTFE)重量百分含量控制在0～40％、全氟乙烯丙烯四氟乙烯六氟丙烯(FEP)重量百分含量控制在0～10％、四氟乙烯全氟烷氧基乙烯基醚共聚物(PFA)重量百分含量控制在0～5％、聚偏氟乙烯(PVDF)重量百分含量控制在0～5％、乙烯四氟乙烯共聚物(ETFE)0～5％重量百分含量控制在和乙烯-三氟氯乙烯共聚物(EDTFE)重量百分含量控制在0～5％。
固体润滑剂选用二硫化钨(WS2)、二硫化钼(MoS2)、石墨(C)、氮化硼(BN)、氟化钙(CaF2)材料中的至少一种；在自润滑耐磨涂层5中二硫化钨(WS2)重量百分含量控制在0～8％、二硫化钼(MoS2)重量百分含量控制在0～8％、石墨(C)重量百分含量控制在0～5％、氮化硼(BN)重量百分含量控制在0～5％、氟化钙(CaF2)重量百分含量控制在0～5％。
无机物选用碳化硅(SiC)、二氧化钛(TiO2)、二氧化硅(SiO2)、三氧化二铝(Al2O3)物质中的至少一种；在自润滑耐磨涂层5中碳化硅(SiC)重量百分含量控制0～3％、二氧化钛(TiO2)重量百分含量控制0～3％、二氧化硅(SiO2)重量百分含量控制0～3％、三氧化二铝(Al2O3)重量百分含量控制0～3％。
本发明所述的自润滑耐磨涂层斜盘的生产工艺，所述自润滑耐磨涂层5是用配制成液态涂料涂上去的，液态涂料的配置方法为：先用溶剂N-甲基吡咯烷酮或二甲基乙酰胺溶解高分子材料，再添加氟塑料、固体润滑剂和耐磨无机物进行充分的搅拌和分散，制成一定含固量的涂料。为增加斜盘金属基体6和自润滑耐磨涂层5的结合强度，金属基体6需通过喷砂、磷化等表面处理工艺。所述自润滑耐磨涂层5采用刷涂或喷涂方式结合在斜盘金属基体6两侧环形平面上，再加热到200℃，保温3个小时，充分挥发溶剂进行烘干；再加热到380℃，保温1小时进行固化、烧结处理而成自润滑耐磨涂层5，自润滑耐磨涂层5经自然冷却后与金属基体6的结合面呈熔融状态。所述金属基体6两侧环形平面上的自润滑耐磨涂层5烧结后最终进行精密加工，自润滑耐磨涂层5的单面厚度控制在0.01～0.1毫米，两个平面的平行度控制在0.01毫米以内。
下面结合具体实施例，进一步阐述本发明。应这样理解下面的实施例，这些实施例仅用于说明本发明而不用于限制本发明的范围。下列实施例中未注明的具体条件的试验方法，通常按照常规条件，或按照制造厂商所建议的条件进行。除非另有说明，否则所有的份数为重量份，所有的百分比为重量百分比。
实施例1
自润滑耐磨涂层涂料由40％杂萘联苯聚醚酮(PPEK)、40％杂萘联苯聚醚砜酮(PPESK)和5％聚四氟乙烯(PTFE)、5％全氟乙烯丙烯四氟乙烯六氟丙烯(FEP)和4％二硫化钨(WS2)、4％二硫化钼(MoS2)和1％三氧化二铝(Al2O3)、1％二氧化钛(TiO2)组成，用溶剂N-甲基吡咯烷酮作为溶剂配置成涂料喷涂在斜盘金属基体6上。在烘箱中烘干烧结，再通过车削和磨削加工成0.02-0.04mm厚度的涂层5。
实施例2
自润滑耐磨涂层涂料由38％杂萘联苯聚醚酮(PPEK)、38％杂萘联苯聚醚砜酮(PPESK)和6％聚四氟乙烯(PTFE)、6％全氟乙烯丙烯四氟乙烯六氟丙烯(FEP)和5％二硫化钨(WS2)、5％二硫化钼(MoS2)和1％碳化硅(SiC)、1％三氧化二铝(Al2O3)组成，用溶剂N-甲基吡咯烷酮作为溶剂配置成涂料喷涂在斜盘金属基体6上。在烘箱中烘干烧结，再通过车削和磨削加工成0.02-0.04mm厚度的涂层5。
实施例3
自润滑耐磨涂层涂料由40％杂萘联苯聚醚酮(PPEK)、40％杂萘联苯聚醚砜(PPES)和5％聚偏氟乙烯(PVDF)、5％全氟乙烯丙烯四氟乙烯六氟丙烯(FEP)和4％二硫化钨(WS2)、4％二硫化钼(MoS2)和1％碳化硅(SiC)、1％二氧化钛(TiO2)组成，用溶剂N-甲基吡咯烷酮作为溶剂配置成涂料喷涂在斜盘金属基体6上。在烘箱中烘干烧结，再通过车削和磨削加工成0.02-0.04mm厚度的涂层5。
实施例4
自润滑耐磨涂层涂料由40％杂萘联苯聚醚酮(PPEK)、40％杂萘联苯聚醚砜(PPES)和5％聚偏氟乙烯(PVDF)、5％全氟乙烯丙烯四氟乙烯六氟丙烯(FEP)和4％石墨(C)、4％二硫化钼(MoS2)和1％碳化硅(SiC)、1％三氧化二铝(Al2O3)组成，用溶剂N-甲基吡咯烷酮作为溶剂配置成涂料喷涂在斜盘金属基体6上。在烘箱中烘干烧结，再通过车削和磨削加工成0.02-0.04mm厚度的涂层5。
为和其他材料有一个对比以显示本发明以上实施例的性能优点，特选聚酰亚胺(PI)和聚醚醚酮(PEEK)替代实施例1中的杂萘联苯聚醚酮(PPEK)和杂萘联苯聚醚砜酮(PPESK)，其他配方材料含量相同，做成试样件做对比试验，具体实施如下：
比较例1
自润滑耐磨涂层涂料由80％聚酰亚胺(PI)和5％聚四氟乙烯(PTFE)、5％全氟乙烯丙烯四氟乙烯六氟丙烯(FEP)和4％二硫化钨(WS2)、4％二硫化钼(MoS2)和1％三氧化二铝(Al2O3)、1％二氧化钛(TiO2)组成，用静电喷涂法把混合材料喷涂在斜盘金属基体上。在烘箱中烘干烧结，再通过车削和磨削加工成0.02-0.04mm厚度的涂层。
比较例2
自润滑耐磨涂层涂料由80％涂料型聚醚醚酮(PEEK)和5％聚四氟乙烯(PTFE)、5％全氟乙烯丙烯四氟乙烯六氟丙烯(FEP)和4％二硫化钨(WS2)、4％二硫化钼(MoS2)和1％三氧化二铝(Al2O3)、1％二氧化钛(TiO2)组成，配置成混合涂料喷涂在斜盘金属基体上。在烘箱中烘干烧结，再通过车削和磨削加工成0.02-0.04mm厚度的涂层。
以上实施例和比较例通过MMU-12端面摩擦磨损试验机考核其摩擦性能，试样件尺寸为37*37*5mm(长×宽×厚度)，试验条件为单位载荷5MPa，线速度1.3m/s，干摩擦，对磨件为40Cr，淬火硬度HRC58-60，试验设定时间120分钟。具体磨损数据见下表：
  磨损量(um)  实际试验时间(min)
  实施例1   12  120
  实施例2   14  120
  实施例3   18  120
  实施例4   16  120
  比较例1   30  58
  比较例2   28  36
通过以上数据可以看出，两种比较例中的产品在不到60分钟的时间内就基本磨光了30um厚度左右的涂层，使试验不得不中止，而本发明的产品有较好的摩擦性能，能完成120分钟的试验，且磨损量较低。
下面为斜盘涂层耐磨抗咬合试验。试验条件为在专用试验设备上，固定斜盘，用三个直径为12mm的半钢球的平面作为对磨件在斜盘上滑动，对磨件和斜盘间的载荷是5N/mm2，对磨件与斜盘的相对运动速度为3.35m/s，干摩擦，测试到斜盘涂层磨光，从而引起对磨件和斜盘基体发生咬合所需的时间，对比试验结果如下：
  发生咬合所需的时间(min)
  实施例1   180
  实施例2   175
  实施例3   162
  实施例4   170
  比较例1   78
  比较例2   42
通过以上数据可以看出，两种比较例中的产品在不到80分钟的时间内就发生对磨件和斜盘基体的咬合，也就是基本磨光了涂层，使试验不得不中止，而本发明的产品有较好的耐磨看咬合性能，抗咬合时间都大于160分钟。

Claims (8)

1.一种自润滑耐磨涂层斜盘，是由金属基体和自润滑耐磨涂层组成，其特征在于在金属基体两侧环形平面上涂有自润滑耐磨涂层，该自润滑耐磨涂层构成所述斜盘环形平面工作层；所述的自润滑耐磨涂层的组成成份包括高分子材料、氟塑料、固体润滑剂及无机物；高分子材料选用杂萘联苯聚醚砜、杂萘联苯聚醚酮、杂萘联苯聚醚砜酮三种材料中的一至三种；在自润滑耐磨涂层中杂萘联苯聚醚砜重量百分含量控制在0～55％、杂萘联苯聚醚酮重量百分含量控制在0～40％、杂萘联苯聚醚砜酮重量百分含量控制在0～15％。
2.根据权利要求1所述的自润滑耐磨涂层斜盘，其特征在于氟塑料选用聚四氟乙烯、全氟乙烯丙烯四氟乙烯六氟丙烯、四氟乙烯全氟烷氧基乙烯基醚共聚物、聚偏氟乙烯、乙烯四氟乙烯共聚物和乙烯-三氟氯乙烯共聚物材料中的至少一种；在自润滑耐磨涂层中聚四氟乙烯重量百分含量控制在0～40％、全氟乙烯丙烯四氟乙烯六氟丙烯重量百分含量控制在0～10％、四氟乙烯全氟烷氧基乙烯基醚共聚物重量百分含量控制在0～5％、聚偏氟乙烯重量百分含量控制在0～5％、乙烯四氟乙烯共聚物重量百分含量控制在0～5％和乙烯-三氟氯乙烯共聚物重量百分含量控制在0～5％。
3.根据权利要求1所述的自润滑耐磨涂层斜盘，其特征在于固体润滑剂选用二硫化钨、二硫化钼、石墨、氮化硼、氟化钙材料中的至少一种；在自润滑耐磨涂层中二硫化钨重量百分含量控制在0～8％、二硫化钼重量百分含量控制在0～8％、石墨重量百分含量控制在0～5％、氮化硼重量百分含量控制在0～5％、氟化钙重量百分含量控制在0～5％。
4.根据权利要求1所述的自润滑耐磨涂层斜盘，其特征在于耐磨无机物选用碳化硅、二氧化钛、二氧化硅、三氧化二铝物质中的至少一种；在自润滑耐磨涂层中碳化硅重量百分含量控制0～3％、二氧化钛重量百分含量控制0～3％、二氧化硅重量百分含量控制0～3％、三氧化二铝重量百分含量控制0～3％。
5.根据权利要求1所述的自润滑耐磨涂层斜盘，其特征在于金属基体为铁基或铁基合金、铜基或铜基合金、铝基或铝基合金、锌基或锌基合金；所述金属基体是通过机械加工方式制成的。
6.根据权利要求1所述的自润滑耐磨涂层斜盘的生产工艺，其特征在于所述自润滑耐磨涂层采用刷涂或喷涂方式结合在斜盘金属基体两侧环形平面上，再加热到200℃，保温3个小时，充分挥发溶剂进行烘干；再加热到380℃，保温1小时进行固化、烧结处理而成自润滑耐磨涂层，自润滑耐磨涂层经自然冷却后与金属基体的结合面呈熔融状态；
所述的溶剂是指N-甲基吡咯烷酮或二甲基乙酰胺，所述自润滑耐磨涂层是用配制成液态涂料涂上去的，液态涂料的配置方法为：先用溶剂溶解高分子材料，再添加氟塑料、固体润滑剂和无机物进行充分的搅拌和分散，制成一定含固量的涂料。
7.根据权利要求6所述的自润滑耐磨涂层斜盘的生产工艺，其特征在于所述金属基体表面通过喷砂、磷化处理。
8.根据权利要求6所述的自润滑耐磨涂层斜盘的生产工艺，其特征在于所述金属基体两侧环形平面上的自润滑耐磨涂层烧结后最终进行精密加工，自润滑耐磨涂层的单面厚度控制在0.01～0.1毫米，两个平面的平行度控制在0.01毫米以内。
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