CN113667522B - 一种抗微动磨损空调电机轴承低噪音润滑脂及其制备方法 - Google Patents
一种抗微动磨损空调电机轴承低噪音润滑脂及其制备方法 Download PDFInfo
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Abstract
本发明提供一种抗微动磨损空调电机轴承低噪音润滑脂及其制备方法。该润滑脂包括以重量百分含量计的以下组分:酯类基础油80%~90%,稠化剂7%~15%,抗氧剂1%~2%,极压抗磨剂1%~2%,防锈剂1~2%;所述酯类基础油选自双酯、三羟甲基丙烷酯和季戊四醇酯中的一种或多种;所述稠化剂为锂皂稠化剂。本发明提供的空调电机轴承润滑脂能够有效解决轴承动磨损问题,同时具备很好的初始静音性能和静音寿命。
Description
技术领域
本发明涉及润滑脂技术领域,尤其涉及一种抗微动磨损空调电机轴承低噪音润滑脂及其制备方法。
背景技术
轴承作为空调电机的配件,对空调性能有重要的影响,轴承的静音和静音寿命直接影响空调的静音性能和免维护性能,由于对声音的直觉性,多年来空调及其风扇电机制造对轴承的初期静音极为重视,近期随着空调市场供求关系变化和性能价格竞争的加剧,对轴承的静音寿命提出了更高要求。空调的使用经常是间隙性的,在北方空调使用频率较高的是夏季,在南方是夏季和冬季,间歇式的使用导致空调在春秋两季长时间不运转,轴承在非工作状态由于外界的振动载荷作用,或其处于微幅摆动工况时,滚动体在滚道的接触区附近会发生微小的相对运动,因运动幅度很小,润滑油无法在接触表面重新分布而使金属表面直接接触,并在氧气的参与下相互作用,故造成接触表面金属的腐蚀,同时产生氧化磨屑,这种现象称为轴承的微动磨损。当微动磨损产生后,空调电机运转会出现异响,影响空调电机的静音寿命,造成较差的客户体验。
微动磨损的产生机理是由于摩擦副表面的润滑不良导致,通过一般的技术方案可以较好的解决问题,例如发明CN111073733A中公开了一种应用于风力发电设备主轴轴承的润滑脂及其制备方法,其包括以下重量份的组分:基础油73~91份、稠化剂8~16份、抗磨减磨剂1~3份、抗氧剂1~5份、极压抗磨剂0.5~2份、防锈剂0.5~1.5份、金属缓蚀剂0.5~1.5份。又如发明CN111607450A公开了一种机器人RV减速器润滑脂及其制备方法,润滑脂按重量份包括如下原料组分制成:脂肪酸8~10份,氢氧化锂1~1.5份,抗氧剂1~2份,防锈剂1~2份,极压抗磨剂3~5份,固体添加剂3~5份及基础油77.2~79.1份。再如发明CN109810745A公开了一种工业机器人谐波减速机专用润滑脂及其制备方法,所述润滑脂由下述重量份数的组分组成:合成基础油75~90份;非金属皂稠化剂3~8份;增粘剂8~20份;引发剂0.5~3份;多效添加剂3~10份;极压抗磨剂1~5份;防锈剂0.5~1.5份。再如发明CN110724577A公开一种润滑脂及其在机器人谐波减速器中的应用,所述润滑脂包括以下组分:以质量分数计,基础油78~86%,稠化剂5~8%,抗氧剂1~3%,极压抗磨剂2.3~4%,固体润滑剂1~3%以及复合磺酸钙基脂4~8%;所述基础油为质量比为2~6∶6∶1~2的矿物油、PAO合成油和酯类油的混合物。再如发明CN108165347A公开了一种汽车座椅滑轨用润滑脂,包括如下质量份的各组分:基础油65份~82份、稠化剂13份~30份、抗氧化剂2.0份~4.0份、防锈剂1.5份~3.0份、极压抗磨剂1.0份~3.0份、阻尼添加剂1.5份~2.0份。发明CN111073733A、CN111607450A、CN109810745A中添加了二烷基二硫代氨基甲酸钼添加剂;上述添加剂在各自领域能起到良好的抗微动磨损作用,但不能应用在空调电机润滑脂中,会影响轴承初始静音性能;发明CN108165347A和CN110724577A中添加了固体润滑剂,同样会影响轴承初始静音性能。上述润滑方案不适用于空调电机润滑领域。
发明CN101087868B中公开了密封在小电动机轴承内以降低噪音的锂润滑脂组合物,包含:5~20wt%增稠剂和95~80wt%基础油,其中所述润滑脂组合物采用锂皂作为增稠剂,它是由氢氧化锂和10~20个碳原子的高级脂肪酸和/或具有1或多个羟基基团和10或更多个碳原子的高级羟基脂肪酸合成的,该基础油包括,作为主要组分,一种聚合物酯油(A),其中8或更多个酯基团以梳齿形式排列在分子链的一侧,用通式1表示:(在式中R1、R2、R3和R4每一个代表烷基基团、x是满足x≥2的整数并且y是满足y≥2的整数),并且该基础油的粘度(40℃)介于25~80mm2/s。但未详述其产品的抗微动磨损能力。类似的低噪音小电动机轴承润滑脂发明也在抗微动磨损能力方面性能较差。目前研发新的抗微动磨损空调电机轴承低噪音润滑脂是本领域亟待解决的重要课题。
发明内容
本发明提供一种抗微动磨损空调电机轴承低噪音润滑脂及其制备方法。本发明提供的空调电机轴承润滑脂可有效解决轴承动磨损问题,同时具备很好的初始静音性能和静音寿命。
本发明提供一种抗微动磨损空调电机轴承低噪音润滑脂,包括以重量百分含量计的以下组分:
所述酯类基础油选自双酯、三羟甲基丙烷酯和季戊四醇酯中的一种或多种;所述稠化剂为锂皂稠化剂。本发明中,采用的空调电机轴承用润滑脂具有优异的抗微动磨损性能和静音性能。尤其是,经研究发现,采用的特定酯类基础油、锂皂稠化剂及上述添加剂在一定用量下复配,所得到的润滑脂能够保证空调电机的长效静音润滑效果,实现终身静音润滑寿命,有效解决轴承微动磨损造成的电机异响,同时具备很好的初始静音性能和静音寿命。
根据本发明提供的所述抗微动磨损空调电机轴承低噪音润滑脂,所述双酯为邻苯二甲酸二丁酯和/或癸二酸二异辛酯。
根据本发明提供的所述抗微动磨损空调电机轴承低噪音润滑脂,所述三羟基及丙烷酯为三羟甲基丙烷三油酸酯和/或三羟甲基丙烷辛酸癸酸酯。
根据本发明提供的所述抗微动磨损空调电机轴承低噪音润滑脂,所述季戊四醇酯选自单季戊四醇辛酸癸酸酯、单季戊四醇油酸酯和双季戊四醇辛酸壬酸酯中的一种或多种。
根据本发明提供的所述抗微动磨损空调电机轴承低噪音润滑脂,酯类基础油组合方式优选为邻苯二甲酸二丁酯、癸二酸二异辛酯中的一种,三羟基及丙烷酯、三羟甲基丙烷三油酸酯、三羟甲基丙烷辛酸癸酸酯中的一种,以及单季戊四醇辛酸癸酸酯、单季戊四醇油酸酯、双季戊四醇辛酸壬酸酯中的一种;优选的,其中每种比例在25%~50%之间。采用上述优选酯类基础油组合方式,与其它组分配合,得到的抗微动磨损空调电机轴承低噪音润滑脂的综合性能及各项效果更优异。
根据本发明提供的所述抗微动磨损空调电机轴承低噪音润滑脂,所述锂皂稠化剂为十二羟基硬脂酸锂皂和/或硬脂酸锂皂。
根据本发明提供的所述抗微动磨损空调电机轴承低噪音润滑脂,所述抗氧剂是二苯胺、辛基丁基二苯胺和二异辛基二苯胺中的一种或多种。
根据本发明提供的所述抗微动磨损空调电机轴承低噪音润滑脂,所述极压抗磨剂选自磷酸酯、硫化烯烃和噻二唑衍生物中的一种或多种。
根据本发明提供的所述抗微动磨损空调电机轴承低噪音润滑脂,所述防锈剂选自二壬基萘磺酸钡和苯并三氮唑和环烷酸锌中的一种或多种。
本发明中,采用酯类油基础油稠化锂基稠化剂,添加了抗氧剂、极压剂和防锈剂,酯类基础油提供良好的基础润滑能力,酯类较强的吸附作用可以牢固的与金属表面接触,形成稳定油膜,减少微动过程中金属与金属的直接接触,添加了抗氧剂和防锈剂能够起到良好的抗老化及防锈作用,优选的极压剂组合能够使得产品具备良好润滑能力的同时提高产品抗微动磨损性能,进一步延长润滑脂的静音寿命。
本发明还提供所述抗微动磨损空调电机轴承低噪音润滑脂的制备方法,包括:按配比量将酯类基础油和锂皂稠化剂混合、搅拌,升温至205~215℃,保温;降温至95~108℃,加入抗氧剂、防锈剂和极压抗磨剂,进行均化处理。
根据本发明提供的所述抗微动磨损空调电机轴承低噪音润滑脂的制备方法,包括:按配比量将酯类基础油和锂皂稠化剂混合、搅拌,以20℃/min的升温速率升温至210℃,保温0~5min;然后降温至100℃,加入抗氧剂、防锈剂和极压抗磨剂,搅拌≥30min,进行均化处理,脱气,得到抗微动磨损空调电机轴承低噪音润滑脂。
本发明中,采用上述方法制备的抗微动磨损空调电机轴承低噪音润滑脂,尤其是采用较快升温速率和润滑脂均化处理,最大程度上较少油脂在炼制过程中的氧化,采用专利方法提供的均化方法能够保证产品具备优秀的静音能力。
本发明的有益效果至少在于:本发明提供的抗微动磨损空调电机轴承低噪音润滑脂组合物选用合适的原料及配比,使得润滑脂具有良好的静音性能,使用生产的润滑脂加入轴承中后,采用SKFBequiet+进行测试,轴承静音等级达到最高的GN4;同时采用美国FALEX微动磨损试验机在频率30HZ,轴承轴向载荷2450N,水平摆动幅度0.21弧度,测试时间22小时条件下,轴承微动磨损量小于5毫克,常规空调电机轴承润滑脂测试后磨损量在70~80毫克左右,有明显的改善,可以保证润滑脂有良好的静音寿命。因此本发明可用于空调电机轴承的长效润滑,能够保证空调电机轴承的初始静音性能和静音寿命。另外本发明的配方原材料为一般石化产品,价格便宜,加工后产品具备较高的性价比,具有广阔的市场空间,本发明制备方法采用一般的反应釜加三重搅拌,没有特殊设备,炼制采用一步法直接升温,工艺简单,节约能耗,产品质量稳定。
具体实施方式
为使本发明的目的、技术方案和优点更加清楚,下面将对本发明中的技术方案进行清楚、完整地描述,显然,所描述的实施例是本发明一部分实施例,而不是全部的实施例。基于本发明中的实施例,本领域普通技术人员在没有作出创造性劳动前提下所获得的所有其他实施例,都属于本发明保护的范围。
实施例中未注明具体技术或条件者,按照本领域内的文献所描述的技术或条件,或者按照产品说明书进行。所用仪器等未注明生产厂商者,均为可通过正规渠道商购买得到的常规产品。所述方法如无特别说明均为常规方法,所述原材料如无特别说明均能从公开商业途径而得。实施例中未注明具体技术或条件者,按照本领域内的文献所描述的技术或条件,或者按照产品说明书进行。
实施例1
本实施例提供一种抗微动磨损空调电机轴承低噪音润滑脂组合物,其制备步骤包括:首先向反应釜中加入邻苯二甲酸二丁酯20g、三羟甲基丙烷三油酸酯20g、单季戊四醇辛酸癸酸酯40g,并投入十二羟基硬脂酸锂15g,以20℃/min的升温速率升温至210℃,并保温5min,将反应釜中物料导入中间釜中,加入二苯胺1g、磷酸酯1g、硫化烯烃1g、二壬基萘磺酸钡1g、苯并三氮唑1g,并搅拌混合30~40min。将物料通过三辊机进行均化处理,并进行脱气制得润滑脂成品。
实施例2
本实施例提供一种抗微动磨损空调电机轴承低噪音润滑脂组合物,其制备步骤包括:首先向反应釜中加入癸二酸二异辛酯20g、三羟甲基丙烷辛酸癸酸酯20g、单季戊四醇油酸酯40g,并投入硬脂酸锂14g,以20℃/min的升温速率升温至210℃,并保温5min,将反应釜中物料导入中间釜中,加入二苯胺1g、辛基丁基二苯胺1g、噻二唑衍生物1g、环烷酸锌1g,并搅拌混合30~40min。将物料通过三辊机进行均化处理,并进行脱气制得润滑脂成品。
实施例3
本实施例提供一种抗微动磨损空调电机轴承低噪音润滑脂组合物,其制备步骤包括:首先向反应釜中加入邻苯二甲酸二丁酯24g、三羟甲基丙烷三油酸酯25g、双季戊四醇辛酸壬酸酯35g,并投入十二羟基硬脂酸锂8g、硬脂酸锂4g,以20℃/min的升温速率升温至210℃,并保温5min,将反应釜中物料导入中间釜中,加入二异辛基二苯胺1g、磷酸酯1g、苯并三氮唑1g、环烷酸锌1g,并搅拌混合30~40min。将物料通过三辊机进行均化处理,并进行脱气制得润滑脂成品。
实施例4
本实施例提供一种抗微动磨损空调电机轴承低噪音润滑脂组合物,其制备步骤包括:首先向反应釜中加入癸二酸二异辛酯26g、三羟甲基丙烷辛酸癸酸酯28g、单季戊四醇辛酸癸酸酯32g,并投入十二羟基硬脂酸锂6g、硬脂酸锂4g,以20℃/min的升温速率升温至210℃,并保温5min,将反应釜中物料导入中间釜中,加入苯胺1g、硫化烯烃1g、二壬基萘磺酸钡1g、环烷酸锌1g,并搅拌混合30~40min。将物料通过三辊机进行均化处理,并进行脱气制得润滑脂成品。
实施例5
本实施例提供一种抗微动磨损空调电机轴承低噪音润滑脂组合物,其制备步骤包括:首先向反应釜中加入邻苯二甲酸二丁酯28g、三羟甲基丙烷三油酸酯24g、单季戊四醇油酸酯36g,并投入十二羟基硬脂酸锂4g、硬脂酸锂4g,以20℃/min的升温速率升温至210℃,并保温5min,将反应釜中物料导入中间釜中,加入辛基丁基二苯胺1g、硫化烯烃1g、噻二唑衍生物1g、二壬基萘磺酸钡1g,并搅拌混合30~40min。将物料通过三辊机进行均化处理,并进行脱气制得润滑脂成品。
实施例6
本实施例提供一种抗微动磨损空调电机轴承低噪音润滑脂组合物,其制备步骤包括:首先向反应釜中加入癸二酸二异辛酯30g、三羟甲基丙烷辛酸癸酸酯30g、单季戊四醇辛酸癸酸酯30g,并投入十二羟基硬脂酸锂3g、硬脂酸锂4g,以20℃/min的升温速率升温至210℃,并保温5min,将反应釜中物料导入中间釜中,加入二异辛基二苯胺1g、磷酸酯1g、苯并三氮唑1g,并搅拌混合30~40min。将物料通过三辊机进行均化处理,并进行脱气制得润滑脂成品。
表1实施例1~6提供的抗微动磨损空调电机轴承低噪音润滑脂组合物
实施例1~6性能数据见表2,其中比较例1为日本某品牌空调电机轴承低噪音润滑脂。
比较例2
为实验室样品,按照以下配方进行调制,首先向反应釜中加入PAO6基础油20g、矿物基础油150N40g、癸二酸二异辛酯30g,并投入十二羟基硬脂酸锂6g、以20℃/min的升温速率升温至210℃,并保温5min,将反应釜中物料导入中间釜中,加入二异辛基二苯胺1g、苯并三氮唑1g,并搅拌混合30~40min。将物料通过三辊机进行均化处理,并进行脱气制得润滑脂成品。
表2实施例中抗微动磨损空调电机轴承低噪音润滑脂与比较例性能数据
从以上实施例和市场上的同类产品比较例的对比数据可以看出:(1)通过Bequiet+测试证明本产品具备较好测初始静音性能,能够达到最高静音等级GN4;(2)通过FALEX微动磨损测试可看出本发明的产品具备较好的抗微动磨损能力,磨损数量显著低于当前市场上竞品,能够实现更长的静音寿命。
最后应说明的是:以上实施例仅用以说明本发明的技术方案,而非对其限制;尽管参照前述实施例对本发明进行了详细的说明,本领域的普通技术人员应当理解:其依然可以对前述各实施例所记载的技术方案进行修改,或者对其中部分技术特征进行等同替换;而这些修改或者替换,并不使相应技术方案的本质脱离本发明各实施例技术方案的精神和范围。
Claims (4)
2.根据权利要求1所述的抗微动磨损空调电机轴承低噪音润滑脂,其特征在于,所述锂皂稠化剂为十二羟基硬脂酸锂皂和/或硬脂酸锂皂。
3.权利要求1或2所述抗微动磨损空调电机轴承低噪音润滑脂的制备方法,其特征在于,包括:按配比量将酯类基础油和锂皂稠化剂混合、搅拌,升温至205~215℃,保温;降温至95~108℃,加入抗氧剂、防锈剂和极压抗磨剂,进行均化处理。
4.根据权利要求3所述的抗微动磨损空调电机轴承低噪音润滑脂的制备方法,其特征在于,包括:按配比量将酯类基础油和锂皂稠化剂混合、搅拌,以20℃/min的升温速率升温至210℃,保温0~5min;然后降温至100℃,加入抗氧剂、防锈剂和极压抗磨剂,搅拌≥30min,进行均化处理,脱气,得到抗微动磨损空调电机轴承低噪音润滑脂。
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