US20150300341A1

US20150300341A1 - Compressor

Info

Publication number: US20150300341A1
Application number: US14/649,115
Authority: US
Inventors: Yoshiyuki Futagami; Yoshinori Ishida; Hiroyuki Fukuhara; Hirotaka Kawabata; Masakazu Yamaoka
Original assignee: Panasonic Intellectual Property Management Co Ltd
Current assignee: Panasonic Corp
Priority date: 2012-12-11
Filing date: 2013-12-11
Publication date: 2015-10-22
Also published as: EP2933489A1; EP2933488A4; WO2014091752A1; EP2933489A4; CN104838140A; WO2014091757A1; CN104838140B; EP2933488A1; JPWO2014091752A1; EP2933488B1; CN104838142A; US20150300340A1; JP6414746B2; JPWO2014091757A1

Abstract

A compressor of the present invention comprises a cylinder (114) which accommodates a reciprocatable piston (116) therein; a valve plate (117) placed at an opening end of the cylinder (114) and includes a discharge valve seat (142) provided to surround a discharge hole (119); and a discharge valve (121) which opens and closes the discharge hole (119), wherein at least one of the discharge valve seat (142) and the discharge valve (121) is provided with a surface treatment film (160) including synthetic resin (171).

Description

TECHNICAL FIELD

The present invention relates to an increase in the efficiency of a compressor which is primarily used in a home refrigerator, and to reduction of a noise in the compressor.

BACKGROUND ART

To achieve energy saving of home refrigerators, there has been an increasing demand for an increase in the efficiency of a compressor by the changeable speed operation of an inverter, an increased changeable speed range realized with sensor control, the use of refrigerant oil with a low viscosity, etc.
An exemplary conventional compressor includes a valve seat plate (valve plate) which has a suction hole which is provided with a valve seat in an opening thereof, and is attached to the end portion of a cylinder, and a suction reed valve which is placed between the end portion of the cylinder and the valve seat plate and opens and closes the suction hole with a lid member (e.g., see Patent Literature 1).
In general, the valve plate has a recess provided with a suction hole, a discharge hole, and a discharge valve. For this reason, the valve plate has a complex shape. To improve a productivity, the valve plate is made of a sintered metal material.

CITATION LIST

Patent Literature

Patent Literature 1: Japanese Laid-Open Patent Application Publication No. 2000-45949

SUMMARY OF INVENTION

Technical Problem

However, since the valve plate is made of the sintered metal material, the valve plate has vacancies which are unique to the sintered metal material. Under the circumstances, the efficiency of the compressor is reduced due to the leakage of the refrigerant through the vacancies, in a discharge valve seat attached to the valve plate to surround the discharge hole. This is a first problem.
If the refrigerant oil (lubricating oil) with a low viscosity is used to achieve energy saving, the lubricating oil staying between the discharge valve seat and the discharge valve is reduced, and thereby the seal performance of the lubricating oil is reduced. This causes the refrigerant (working fluid) to flow back. As a result, the efficiency of the compressor is reduced significantly.
When the discharge valve being closed hits the discharge valve seat, a hit noise is generated and leaks to outside a sealed container, and as a result, a noise is generated. This is a second problem.
In a case where inverter driving for electric components is used to attain the high efficiency of the compressor, a noise generated in the electric components is reduced when the compressor is operated at a low speed. In this case, a noise generated when the discharge valve hits the discharge valve seat is noticeable, which causes a noise. In a case where the compressor is incorporated into a home refrigerator which is placed in a room in most cases, a noise must be reduced.
Moreover, in a case where a suction valve seat is provided in the valve plate so as to surround the suction hole, it is likely that the first or second problem also arises between the suction valve seat and the suction valve.
An object of the present invention is to provide a compressor which is capable of solving at least one of the above described two problems.

Solution to Problem

A compressor of the present invention comprises a cylinder which accommodates a reciprocatable piston therein; a valve plate placed at an opening end of the cylinder and includes a discharge valve seat provided to surround a discharge hole; and a discharge valve which opens and closes the discharge hole, wherein at least one of the discharge valve seat and a portion of the discharge valve which portion contacts the discharge valve seat is provided with a surface treatment film including synthetic resin.
In this configuration, since the surface treatment film seals many vacancies which are unique to a sintered metal material and are present in the discharge valve seat, the leakage of refrigerant from the discharge valve seat can be reduced, and a seal performance can be improved. Because of the improvement of the seal performance, it becomes possible to suppress a working fluid from flowing back during a suction stroke. As a result, the efficiency of the compressor can be improved.
In addition, the surface treatment film is able to elastically reduce a hit force generated when the discharge valve closes the discharge hole, and thereby reduce the hit noise. As a result, the noise of the compressor can be reduced.
A compressor of the present invention comprises a cylinder which accommodates a reciprocatable piston therein; a valve plate placed at an opening end of the cylinder and includes a suction valve seat provided to surround a suction hole; and a suction valve which opens and closes the suction hole, wherein at least one of the suction valve seat and a portion of the suction valve which portion contacts the suction valve seat is provided with a surface treatment film including synthetic resin.
In this configuration, since the surface treatment film seals many vacancies which are unique to a sintered metal material and are present in the suction valve seat, the leakage of refrigerant from the suction valve seat can be reduced, and a seal performance can be improved. Because of the improvement of the seal performance, it becomes possible to suppress a working fluid from flowing back during a suction stroke. As a result, the efficiency of the compressor can be improved.
In addition, the surface treatment film is able to elastically reduce a hit force generated when the suction valve closes the suction hole, and thereby reduce the hit noise. As a result, the noise of the compressor can be reduced.

Advantageous Effects of Invention

The compressor of the present invention is capable of reducing the leakage of refrigerant from the discharge valve seat, and improve a seal performance for the discharge valve seat and the discharge valve. Therefore, the compressor with increased efficiency can be realized.
In addition, the compressor of the present invention is capable of reducing a hit noise generated when the discharge valve closes the discharge hole. Therefore, the compressor which can reduce a hit noise can be realized.
The compressor of the present invention is capable of reducing the leakage of refrigerant from the suction valve seat, and improve a seal performance for the suction valve seat and the suction valve. Therefore, the compressor with high efficiency can be realized. In addition, the compressor of the present invention is capable of reducing a hit noise generated when the suction valve closes the suction hole. Therefore, the compressor with a low noise which can reduce a hit noise can be realized.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 is a vertical sectional view of a compressor according to Embodiment 1.

FIG. 2 is an exploded perspective view of a valve plate and members which are present in the vicinity of the valve plate, of the compressor of FIG. 1.

FIG. 3 is a cross-sectional view of the major components of the compressor of FIG. 1.

FIG. 4 is an enlarged cross-sectional view of A-part of FIG. 3.

FIG. 5 is a cross-sectional view of a surface treatment film and a suction valve seat of the compressor according to Embodiment 1.

FIG. 6 is a cross-sectional view of a suction valve seat (contact member) of a compressor according to Embodiment 2.

FIG. 7 is a cross-sectional view of a suction valve seat (contact member) of a compressor according to Modified example 1 of Embodiment 2.

FIG. 8 is a cross-sectional view of the major components of a compressor according to Embodiment 3.

FIG. 9 is an enlarged cross-sectional view of B-part of FIG. 8.

FIG. 10 is a cross-sectional view of the major components of a compressor according to Embodiment 4.

FIG. 11 is a cross-sectional view of a discharge valve seat (contact member) of the compressor according to Embodiment 4.

FIG. 12 is a cross-sectional view of the major components of a compressor according to Embodiment 5.

FIG. 13 is a plan view of a suction valve of FIG. 12.

FIG. 14 is a cross-sectional view of a suction valve (contact member) of a compressor according to Embodiment 6.

FIG. 15 is a cross-sectional view of the major components of a compressor according to Embodiment 7.

FIG. 16 is a plan view of a discharge valve of FIG. 15.

FIG. 17 is a cross-sectional view of a discharge valve (contact member) of a compressor according to Embodiment 8.

FIG. 18 is a cross-sectional view of the major components of a compressor according to Embodiment 9.

FIG. 19 is a cross-sectional view of the major components of a compressor according to Embodiment 10.

FIG. 20 is a vertical sectional view of a compressor according to Embodiment 11.

FIG. 21 is an enlarged cross-sectional view of C-part of FIG. 20.

FIG. 22 is a schematic view showing the major components of the compressor in a state in which a main shaft is sliding in the state of partial contact with a bearing section.

FIG. 23 is a cross-sectional view of a main shaft (slide member) of the compressor according to Modified example 1 of Embodiment 11.

FIG. 24 is a vertical sectional view of a compressor according to Embodiment 12.

FIG. 25 is an enlarged cross-sectional view of D-part of FIG. 24.

FIG. 26 is a schematic view showing the configuration of a pneumatic syringe dispenser device.

FIG. 27 is a schematic view showing the outline of manufacturing a surface treatment film, by using the device of FIG. 26.

FIG. 28 is a vertical sectional view of a compressor according to Modified example 1 of Embodiment 12.

FIG. 29 is an enlarged cross-sectional view of E-part of FIG. 28.

DESCRIPTION OF EMBODIMENTS

Hereinafter, the embodiments of the present invention will be described with reference to the drawings. Throughout the drawings, the same or corresponding components are designated by the same reference symbols and will not be described repeatedly. Throughout the drawings, the elements required to explain the present invention are shown and the other elements are not shown in some cases. Furthermore, the present invention is not limited to the embodiments described below.

Embodiment 1

A compressor according to Embodiment 1 comprises a cylinder which accommodates a reciprocatable piston therein; a valve plate placed at an opening end of the cylinder and includes a suction valve seat provided to surround a suction hole; and a suction valve which opens and closes the suction hole, wherein at least one of the suction valve seat and a portion of the suction valve which portion contacts the suction valve seat is provided with a surface treatment film including synthetic resin.
In the compressor according to Embodiment 1, the surface treatment film may include a solid lubricant.
In the compressor according to Embodiment 1, the surface treatment film may have a thickness of 1 μm to 20 μm.
In the compressor according to Embodiment 1, the synthetic resin may comprise at least one resin selected from a resin group consisting of polyamide resin, epoxy resin, and phenol resin.
In the compressor according to Embodiment 1, the solid lubricant may comprise at least one compound selected from a compound group consisting of molybdenum disulfide, graphite, polytetrafluoroethylene resin, and antimony trioxide.
Now, as an exemplary compressor according to Embodiment 1, a compressor including a suction valve seat provided with a surface treatment film will be described with reference to FIGS. 1 to 5.
[Configuration of Compressor]
FIG. 1 is a vertical sectional view of a compressor according to Embodiment 1. FIG. 2 is an exploded perspective view of a valve plate and members which are present in the vicinity of the valve plate, of the compressor of FIG. 1. FIG. 3 is a cross-sectional view of the major components of the compressor of FIG. 1. FIG. 4 is an enlarged cross-sectional view of A-part of FIG. 3.
As shown in FIG. 1, a sealed compressor 100 according to Embodiment 1 includes a sealed container 101 and a compressor body 104 accommodated into the sealed container 101. The sealed container 101 is filled with, for example, refrigerant (working fluid) 103. Lubricating oil (refrigerant oil) 102 is stored in a bottom portion of the sealed container 101. As the lubricating oil 102, for example, mineral oil with a low viscosity may be used. As the refrigerant 103, for example, hydrocarbon-based R600a (isobutane) with a low global warming potential may be used.
The sealed container 101 is manufactured by a drawing process of an iron plate. The sealed container 101 is provided with a suction pipe 150 and a discharge pipe 157. One end of the suction pipe 150 is in communication with the interior of the sealed container 101, and the other end of the suction pipe 150 is connected to an evaporator (not shown) at the low-pressure side of a refrigeration cycle via a suitable pipe. One end of the discharge pipe 157 is in communication with a discharge muffler (not shown), and the other end of the discharge pipe 157 is connected to a condenser (not shown) at the high-pressure side of a refrigeration cycle via a suitable pipe.
The compressor body 104 includes a compression component 109 and an electric component 106, and is elastically supported on the sealed container 101 by a suspension spring 105. In Embodiment 1, the electric component 106 is placed below the compression component 109 (at a lower side in the interior of the sealed container 101), and includes a stator 107 and a rotor 108.
The stator 107 is threadingly fastened to the lower side of a block 115 (described later) by means of a bolt (not shown). The rotor 108 is fastened to the main shaft 111 as will be described later such that the rotor 108 is coaxial with the stator 107, in a position inward relative to the stator 107, by shrink-fitting or press-in. The electric component 106 is configured to be activated in any one of plural operation frequencies including an operation frequency (e.g., 25 Hz=1500 r/min) which is lower than a utility power supply frequency, by an inverter driving circuit.
The compression component 109 includes a crankshaft 112, the block 115, a piston 116, a connecting means (connecting rod) 122, and others. The crankshaft 112 includes the main shaft 111 having a center axis vertically extending, an eccentric shaft 110 connected to the lower end of the main shaft 111, and an oil feeding mechanism 151. The oil feeding mechanism 151 includes a spiral groove 183 (see FIG. 20) provided on the surface of the main shaft 111, etc. The oil feeding mechanism 151 is configured to feed the lubricating oil 102 to a bearing section (main bearing) 123, the connecting means 122, and others.
The block 115 is provided with a cylinder 114 defining a compression chamber 113 and the bearing section 123 to which the main shaft 111 is rotatably mounted such that the cylinder 114 and the bearing section 123 are integrated with the block 115. The piston 116 is inserted into the cylinder 114 such that the piston 116 is extendable and retractable. The eccentric shaft 110 is connected to the piston 116 via the connecting means 122.
As shown in FIGS. 1 and 2, a suction valve 120, a valve plate 117 and a cylinder head 152 are provided on the end surface of the cylinder 114. Specifically, the suction valve 120, the valve plate 117, and the cylinder head 152 are placed in this order, from the perspective of the end surface of the cylinder 114. These members are pressingly fastened to the end surface of the cylinder 114 by a head bolt 153 such that these members seal the end surface of the cylinder 114.
A suction muffler 154 is retained between the valve plate 117 and the cylinder head 152 (see FIG. 1). A head space 156 is defined by the valve plate 117 and the cylinder head 152.
The valve plate 117 is molded by using a sintered metal material, and the main surface of the valve plate 117 which is closer to the cylinder head 152 is provided with a recess 132 (see FIG. 2). The bottom surface of the recess 132 has a discharge hole 119 which allows communication between the interior and exterior of the compression chamber 113. The bottom surface of the recess 132 is provided with a ring-shaped discharge valve seat 142 which contacts the discharge valve 121.
The discharge valve 121 which opens and closes the discharge hole 119, a spring reed 130 which elastically supports the discharge valve 121, and a valve stop 131 for fastening the discharge valve 121 and the spring reed 130 to each other are placed in the recess 132.
The main surface of the valve plate 117 has a suction hole 118 which allows communication between the interior and the exterior of the compression chamber 113. The suction hole 118 has a shape in which its opening which is closer to the cylinder 114 is larger than its opening which is closer to the cylinder head 152. A ring-shaped suction valve seat 141 is provided on the opening of the suction hole 118, which is closer to the cylinder 114, in the valve plate 117, so as to surround the suction hole 118.
The suction valve 120 is formed of a steel metal, and is configured to open and close the suction hole 118. Specifically, a U-shaped opening/closing section 120 a is provided on the suction valve 120 in a location corresponding to the discharge hole 119. The U-shaped opening/closing section 120 a is adapted to contact the suction valve sheet 141 of the valve plate 117. A surface treatment film 160 is provided on the suction valve seat 141 (to be precise, outer surface of the suction valve seat 141) of the valve plate 117. In Embodiment 1, the surface treatment film 160 is composed of a single coating layer.
[Configuration of Surface Treatment Film]
Next, the configuration of the surface treatment film 160 of the compressor 100 according to Embodiment 1 will be described in detail with reference to FIGS. 1 to 5. FIG. 5 is a cross-sectional view of the surface treatment film and the suction valve seat of the compressor according to Embodiment 1.
As shown in FIGS. 1 to 5, the surface treatment film 160 is provided so as to surround the suction hole 118. In Embodiment 1, the surface treatment film 160 has a ring-shape. The surface treatment film 160 may have any shape so long as it surrounds the suction hole 118, and may have, for example, a rectangular shape.
The surface treatment film 160 may be coplanar with the main surface of the valve plate 117 (main surface which is closer to the cylinder 114), or may protrude from the main surface of the valve plate 117. The thickness of the surface treatment film 160 may be set equal to or larger than 1 μm for the improvement of the seal performance. To allow the surface of the surface treatment film 160 to be located within the dimension tolerance of the main surface of the valve plate 117, the thickness of the surface treatment film 160 may be set equal to or smaller than 20 μm.
The surface treatment film 160 includes synthetic resin 161. In Embodiment 1, the synthetic resin 161 comprises polyamide-imide (PA1). The surface treatment film 160 includes a solid lubricant 162. In Embodiment 1, the solid lubricant 162 comprises molybdenum disulfide (MoS₂). More specifically, in Embodiment 1, the surface treatment film 160 includes the synthetic resin 161 comprising polyamide-imide (PAI) as a binder, and molybdenum disulfide particles as the solid lubricant 162 which are dispersed substantially uniformly in the synthetic resin 161.
Although in Embodiment 1, the synthetic resin 161 comprising polyamide-imide is used as the binder, the present invention is not limited to this. The synthetic resin 161 may be any resin so long as it is thermosetting resin and has a high resistance to oil, heat, refrigerant, and an organic agent. The synthetic resin 161 may comprise at least one resin selected from a resin group consisting of polyamide resin, epoxy resin, and phenol resin.
Although in Embodiment 1, molybdenum disulfide (MoS₂) is used as the solid lubricant 162 dispersed in the surface treatment film 160, the present invention is not limited to this. The solid lubricant 162 may comprise at least one compound selected from a compound group consisting of molybdenum disulfide, graphite (G), polytetrafluoroethylene resin (PTFE), and antimony trioxide (Sb₂O₃).
In a case where molybdenum disulfide and/or graphite is used as the solid lubricant 162, the surface treatment film 160 may also comprise antimony trioxide. In this case, antimony trioxide captures air or oxygen which has entered the surface treatment film 160 and is oxidated. This makes it possible to suppress the change of properties of molybdenum disulfide and/or graphite, which would otherwise occur due to oxidation. Thus, the abrasion of the surface treatment film 160 can be suppressed effectively.
[Manufacturing Method of Surface Treatment Film]
Next, the manufacturing method of the surface treatment film 160 will be described.
Initially, preliminary heating is conducted to increase the temperature of the valve plate 117 up to a predetermined temperature (only a region which is in the vicinity of the suction valve seat 141 may be heated in this heating). This is intended to vaporize an organic solvent dissolving (solving) in the surface treatment film 160 applied on the suction valve seat 141 so that the surface treatment film 160 is applied uniformly to the suction valve seat 141.
Then, prepared is a surface treatment agent (coaling agent) with a specified viscosity which is produced by adjusting a liquid agent including the synthetic resin 161 and the solid lubricant 162 dispersed in the synthetic resin 161 with a diluting agent comprising an organic solvent. Then, this surface treatment agent is applied to the suction valve seat 141 of the valve plate 117 by spraying. To prevent the surface treatment agent from adhering onto a region which does not require the application of the surface treatment agent, the valve plate 117 may be attached with a masking jig of a suitable shape, or the surface treatment agent may be applied to the suction valve seat 141 by using the pneumatic syringe dispenser device.
Thereafter, drying is temporarily conducted for several minutes under a temperature which is substantially as high as the temperature in the preliminary heating to dry the surface of the surface treatment film 160. At a stage in which the surface of the surface treatment film 160 is dried, buffing is conducted a little in order to finely adjust the surface roughness of the outer surface of the surface treatment film 160 into good one. Desirably, a buff used in the buffing is a horse hair buff, rather than a nylon buff containing abrasive grains or a relatively hard steel buff.
Finally, calcining is conducted under a temperature of about 180 degrees C. to 230 degrees C. for about 30 minutes to 2 hours, to vaporize all of the diluting agent in the surface treatment agent. In this way, the surface treatment film 160 is allowed to completely adhere to the suction valve seat 141.
[Operation of Compressor]
Next, the operation of the sealed compressor 100 according to Embodiment 1 will be described with reference to FIGS. 1 to 4.
Initially, when the electric component 106 is applied with a current, the current flows through the stator 107, to generate a magnetic field, causing the rotor 108 fastened to the main shaft 111 to rotate. According to the rotation of the rotor 108, the crankshaft 112 rotates, and the rotational motion of the eccentric shaft 110 is converted into a linear reciprocation motion via the connecting means 122. The piston 116 reciprocates within the cylinder 114.
According to the reciprocation motion of the piston 116, the refrigerant 103 is suctioned into the interior of the compression chamber 113 via the suction muffler 154. The refrigerant 103 suctioned into the interior of the compression chamber 113 is compressed therein and thereafter is discharged to a refrigeration cycle (not shown) through the discharge hole 119 and the head space 156. The refrigerant 103 discharged to the refrigerant cycle performs heat exchange while it is flowing through the refrigeration cycle, and is suctioned into the compression chamber 113 again.
Next, the suction stroke and the compression stroke of the compressor 100 will be described more specifically.
In the suction stroke, when the piston 116 moves in a direction to increase the volume of the compression chamber 113, the refrigerant 103 in the interior of the compression chamber 113 expands. When a pressure in the interior of the compression chamber 113 falls below a pressure in the interior of the suction muffler 154, the suction valve 120 starts to be opened due to a difference between the pressure in the interior of the compression chamber 113 and the pressure in the interior of the suction muffler 154. According to this operation, the low-temperature refrigerant 103 which has returned from the refrigeration cycle is released to the interior of the sealed container 101 from the suction pipe 150. Then, the refrigerant 103 flows into the compression chamber 113 through the suction muffler 154.
After that, in the compression stroke, when the piston 116 moves from the bottom dead center in a direction to reduce the volume of the interior of the compression chamber 113, the pressure in the interior of the compression chamber 113 is increased. Due to a difference between the pressure in the interior of the compression chamber 113 and the pressure in the interior of the suction muffler 154, the suction valve 120 is closed, and thereby the compression chamber 113 is closed. When the piston 116 moves in the direction to reduce the volume of the interior of the compression chamber 113, the refrigerant 103 is compressed, and the pressure in the interior of the compression chamber 113 is increased to a specified pressure.
In the discharge stroke, when the pressure of the refrigerant 103 in the interior of the compression chamber 113 is increased, becomes higher the pressure in the interior of the head space 156, and exceeds a force for elastically deforming the discharge valve 121, the discharge hole 119 is opened. Thereby, the refrigerant 103 in the interior of the compression chamber 113 flows into the head space 156 through the discharge hole 119. Then, the refrigerant 103 flows through the head space 156 and a discharge muffler (not shown), and is discharged to the high-pressure side (not shown) of the refrigeration cycle through the discharge pipe 157.
When a pressure difference between the head space 156 and the compression chamber 113 is decreased, and a force generated due to the pressure difference and applied to the discharge valve 121 becomes smaller than the restoration force of the spring reed 130 and the discharge valve 121, the discharge valve 121 is closed, the compression chamber 113 is closed, and the piston 116 moves toward the bottom dead center. Thus, the discharge stroke shifts to the suction stroke again.
[Advantage of Compressor]
Next, the advantage of the compressor 100 according to Embodiment 1 will be described with reference to FIGS. 1 to 5.
In general, the valve plate 117 is provided with the suction valve seat 141, the discharge valve seat 142, etc., and therefore has a complex shape. To improve a productivity, and reduce cost, the valve plate 117 is molded using a sintered metal material.
Since the sintered metal material is typically molded by pouring metal powder into a die, then pressurizing the metal powder and heating the metal powder, it has continuous vacancies on its surface and inside thereof. For this reason, the efficiency of the compressor may be reduced, due to the leakage of the refrigerant through the vacancies.
When the refrigerant oil 102 with a low viscosity is used to achieve energy saving, the lubricating oil 102 staying between the suction valve seat 141 and the suction valve 120 is reduced, and the seal performance for the suction valve seat 141 and the suction valve 120 which is attained by the lubricating oil 102 is reduced. This causes the refrigerant 103 to flow back. As a result, the efficiency of the compressor is reduced significantly.
To solve this problem, the pressurization step and heating step performed for molding the sintered metal material may be repeated plural times. This can increase the density of the sintered metal material, and reduce the size of the vacancies of the sintered metal material. However, cost increases and the sintered metal material cannot be easily processed. In a case where a cast iron material is used, plural locations are required to be processed, and processing cost increases.
In view of the above stated circumstances, in the compressor 100 according to Embodiment 1, the suction valve seat 141 is provided with the surface treatment film 160 including the synthetic resin 161, to seal many vacancies which are unique to the sintered metal material and are present in the suction valve seat 141, with the surface treatment film 160 including the synthetic resin 161. This can reduce the leakage of the refrigerant 103 from the suction valve seat 141. As result, reduction of the efficiency of the compressor 100 can be suppressed.
In addition, in the compressor 100 according to Embodiment 1, since the suction valve seat 141 is provided with the surface treatment film 160 including the synthetic resin 161, the seal performance for the suction valve seat 141 and the suction valve 120 can be improved. Because of this, it becomes possible to suppress the back-flow of the refrigerant 103 during the compression stroke and the discharge stroke.
Therefore, the compressor 100 according to Embodiment 1 is capable of suppressing reduction of a refrigeration capability and increasing the efficiency at low cost.
In the compressor 100 according to Embodiment 1, since the suction valve seat 141 is provided with the surface treatment film 160 including the synthetic resin 161, the surface treatment film 160 is able to elastically reduce a hit force generated when the suction valve 120 closes the suction valve seat 141. Therefore, a hit noise can be reduced, and the compressor with a low noise can be realized.
Since the hit force generated when the suction valve 120 closes the suction valve seat 141 can be reduced, damages to the suction valve 120 such as break or crack can be lessened. As a result, the performance of the compressor 100 can be maintained for a long period of time.
In the compressor 100 according to Embodiment 1, since the surface treatment film 160 includes the solid lubricant 162 with a lipophilic property, the lubricating oil 102 with a sufficient amount can stay between the suction valve seat 141 (to be precise, the surface treatment film 160 provided on the outer surface of the suction valve seat 141) and the suction valve 120. This can improve the seal performance for the suction valve seat 141 and the suction valve 120, and hence suppress the back-flow of the refrigerant 103 during the compression stroke and the discharge stroke.
In the compressor 100 according to Embodiment 1, since the surface treatment film 160 includes the solid lubricant 162, a shear force generated when the suction valve 120 closes the suction valve seat 141 can be reduced because of the lubrication of the solid lubricant 162. This can suppress separation between the surface (outer surface) of the suction valve seat 141 and the inner surface of the surface treatment film 160. As a result, it becomes possible to realize the compressor 100 with a high durability which can withstand long-time use.
When the surface treatment film 160 is caused to adhere onto the suction valve seat 141, the outer surface of the surface treatment film 160 has minute concave-convex portions. However, in the compressor 100 according to Embodiment 1, the surface treatment film 160 includes the solid lubricant 162. The solid lubricant 162 is higher in strength than the synthetic resin 161. Therefore, when the compressor 100 is operated, the concave-convex portions formed on the outer surface of the surface treatment film 160 vanish at an earlier time, so that the outer surface of the surface treatment film 160 can be made smooth. Therefore, the seal performance for the suction valve seat 141 and the suction valve 120 can be improved.
In the compressor 100 according to Embodiment 1, by setting the thickness of the surface treatment film 160 to 1 μm or larger, the surface treatment film 160 can be formed on the suction valve seat 141 uniformly. Also, by setting the thickness of the surface treatment film 160 to 20 μm or smaller, the internal strength of the surface treatment film 160 and the adhesion strength of the surface treatment film 160 with a base member interface can be ensured, and the rough state of the surface treatment film 160 can be lessened while ensuring a durability.
In the manufacturing method of the compressor 100 according to Embodiment 1, the surface treatment agent is applied to only regions which require the application of the surface treatment agent, by using the suitable masking jig, the pneumatic syringe dispenser device, etc. Because of this, the surface treatment agent to be used can be reduced in amount. In this way, the compressor 100 with a high productivity and low cost can be realized.

Embodiment 2

A contact member according to Embodiment 2 comprises a surface treatment film including two or more coating layers stacked together, in at least a portion of a contact surface thereof, each of the coating layers includes synthetic resin and a solid lubricant, and the solid lubricant of the coating layer located at an innermost side is lower in content percentage than the solid lubricant of the coating layer located at an outermost side.
In the contact member according to Embodiment 2, the solid lubricant may comprise at least one compound selected from a compound group consisting of molybdenum disulfide, graphite, polytetrafluoroethylene resin, and antimony trioxide.
In the contact member according to Embodiment 2, the solid lubricant of the coating layer located at the innermost side may be smaller in average particle (grain) diameter than the solid lubricant of the coating layer located at the outermost side. As defined herein, the content percentage of the solid lubricant in the coating layer refers to a ratio of the volume of the solid lubricant with respect to the unit volume of the coating layer (volume percentage; vol/vol).
In the contact member according to Embodiment 2, the solid lubricant of the coating layer located at the innermost side may be smaller in weight than the solid lubricant of the coating layer located at the outermost side.
A contact member according to Embodiment 2 comprises a surface treatment film including two or more coating layers stacked together, in at least a portion of a contact surface thereof, each of the coating layers includes synthetic resin, and the coating layer located at the innermost side is larger in elastic deformation amount than the coating layer located at the outermost side.
In the contact member according to Embodiment 2, the thickness of the surface treatment film may be set to 1 to 30 nm.
In the contact member according to Embodiment 2, the synthetic resin may comprise at least one resin selected from a resin group consisting of polyamide resin, epoxy resin, and phenol resin.
A compressor according to Embodiment 2 comprises a cylinder which accommodates a reciprocatable piston therein; a valve plate placed at an opening end of the cylinder and includes a suction hole, a suction valve seat provided to surround the suction hole, a discharge hole, and a discharge valve seat provided to surround the discharge hole, a suction valve which opens and closes the suction hole, and a discharge valve which opens and closes the discharge hole, wherein at least one of the suction valve seat, the discharge valve seat, the suction valve, and the discharge valve comprises the above contact member.
A manufacturing method of a compressor according to Embodiment 2 comprises (A) applying a first surface treatment agent including synthetic resin and a solid lubricant to at least a portion of a contact surface thereof to form a first coating layer; and (B) applying onto the first coating layer a second surface treatment agent including a solid lubricant with a larger average particle diameter than that of the solid lubricant of the first surface treatment agent to form a second coating layer.
Now, as an exemplary contact member according to Embodiment 2, a case where the contact member is the suction valve seat will be described with reference to FIG. 6. The configuration of the compressor according to Embodiment 2 is the same as that of the compressor according to Embodiment 1, and therefore will not be described in detail repeatedly.
[Configuration of Compressor (Contact Member)]
FIG. 6 is a cross-sectional view of the suction valve seat (contact member) of the compressor according to Embodiment 2.
As shown in FIG. 6, the configuration of the surface treatment film 160 provided on the suction valve seat (contact member) of the compressor 100 according to Embodiment 2 is basically the same as that of the surface treatment film 160 of the compressor 100 according to Embodiment 1, except that the surface treatment film 160 has a two-layer structure including a first coating layer 160 a and a second coating layer 160 b.
Specifically, the first coating layer 160 a is located at the outer surface side of the suction valve seat 141 (innermost side), while the second coating layer 160 b is located outward relative to the first coating layer 160 a (outermost side). In Embodiment 2, the first coating layer 160 a and the second coating layer 160 b are formed on the outer surface of the suction valve seat 141 so as to conform in shape to the outer surface of the suction valve seat 141.
The first coating layer 160 a includes the synthetic resin 161 comprising polyamide-imide (PAI) as the binder, and the solid lubricant 162 which has an average particle diameter of 1 μm or smaller and is dispersed substantially uniformly in the synthetic resin 161 such that the solid lubricant 162 in the first coating layer 160 a has a content percentage which is smaller than 33%. As in the first coating layer 160 a, the second coating layer 160 b includes the synthetic resin 161 comprising polyamide-imide (PAI) as the binder, and the solid lubricant 162 which has an average particle diameter of 3 nm or larger and 5 nm or smaller and is dispersed substantially uniformly in the synthetic resin 161 such that the solid lubricant 162 in the second coating layer 160 b has a content percentage which is equal to or larger than 33%.
Since the solid lubricant 162 is higher in mechanical strength than the synthetic resin 161, the elastic deformation amount of the first coating layer 160 a can be made larger than that of the second coating layer 160 b by setting the content percentage of the solid lubricant 162 in the first coating layer 160 a lower than that of the solid lubricant 162 in the second coating layer 160 b.
Or, the content percentage of the solid lubricant 162 in the first coating layer 160 a may be made lower than that of the solid lubricant 162 in the second coating layer 160 b by setting the quantity (weight) of the solid lubricant 162 in the first coating layer 160 a smaller than that of the solid lubricant 162 in the second coating layer 160 b, under the condition in which the average particle diameter of the synthetic resin 161 is set equal.
Or, the elastic deformation amount of the first coating layer 160 a may be be made larger than that of the second coating layer 160 b by changing the kind and/or content percentage of the synthetic resin 161 included in the coating layers. In this case, the coating layer may not include the solid lubricant 162. For example, the first coating layer 160 a may comprise the phenol resin having a relatively soft property to increase the elastic deformation amount, while the second coating layer 160 b may comprise polyamide resin having a relatively hard property to reduce the elastic deformation amount.
To maintain the performance of the compressor 100 for a long period of time, the content percentage of the solid lubricant 162 in the first coating layer 160 a may be equal to or larger than 1% and smaller than33%.
As shown in FIG. 6, the surface treatment film 160 is configured such that the thickness of the first coating layer 160 a is smaller than the thickness of the second coating layer 160 b and set to about 10 μm in Embodiment 2.
Although in Embodiment 2, the thickness of the first coating layer 160 a is set smaller than the thickness of the second coating layer 160 b, the present invention is not limited to this. The thickness of the first coating layer 160 a may be equal to or larger than that of the second coating layer 160 b.
Although in Embodiment 2, the thickness of the surface treatment film 160 is set to about 10 μm, the present invention is not limited to this. To improve the seal performance, the thickness of the surface treatment film 160 may be equal to or larger than 1 μm, while to manufacture the surface treatment film 160 efficiently, the thickness of the surface treatment film 160 may be equal to or smaller than 30 μm. To mitigate an impact force applied to the surface treatment film 160 and to manufacture the surface treatment film 160 efficiently, the thickness of the surface treatment film 160 may be equal to or larger than 5 μm and equal to or smaller than 20 μm.
[Manufacturing Method of Surface Treatment Film]
Next, the manufacturing method of the surface treatment film 160 will be described.
Initially, preliminary heating is conducted to increase the temperature of the valve plate 117 up to a predetermined temperature (only a region which is in the vicinity of the suction valve seat 141 may be heated in this heating). This is intended to vaporize an organic solvent dissolving (solving) in the surface treatment film 160 applied to the suction valve seat 141 so that the surface treatment film 160 is applied uniformly to the suction valve seat 141.
Then, prepared is a first surface treatment agent for the first coating layer 160 a with a specified viscosity and a second surface treatment agent for the second coating layer 160 b with a specified viscosity, each of which is produced by adjusting a liquid agent including the synthetic resin 161 and the solid lubricant 162 dispersed in the synthetic resin 161 with a diluting agent comprising an organic agent. Then, the first surface treatment agent is applied to the suction valve seat 141 of the valve plate 117 by spraying. To prevent the first surface treatment agent from adhering onto a region which does not require the application of the first surface treatment agent, the valve plate 117 may be attached with a masking jig of a suitable shape, or the first surface treatment agent may be applied to the suction valve seat 141 by using the pneumatic syringe dispenser device.
Thereafter, drying is temporarily conducted for several minutes under a temperature which is slightly higher than the temperature in the preliminary heating, to cure the surface of the first coating layer 160 a. Then, the second surface treatment agent is applied to the surface of the first coating layer 160 a by spraying.
Then, drying is temporarily conducted for several minutes under a temperature which is slightly higher than the temperature in the preliminary heating. At a stage in which the surface of the second coating layer 160 b is cured, i.e., dried so that liquid resin does not adhere to a finger when the finger touches the surface applied with the second coating layer 160 b), buffing is conducted a little in order to finely adjust the surface roughness of the surface treatment film 160 (outer surface of the second coating layer 160 b). Desirably, the buff used in the buffing is the horse hair buff, rather than the nylon buff containing abrasive grains or the relatively hard steel buff.
Finally, calcining is conducted under a temperature of about 200 degrees C. to 250 degrees C. for about 30 minutes to 2 hours, to vaporize all of the diluting agent in the surface treatment agent. In this way, the surface treatment film 160 including the two coating layers is allowed to completely adhere to the suction valve seat 141.
[Advantage of Compressor]
Next, the advantage of the compressor 100 according to Embodiment 2 will be described with reference to FIG. 6.
In the compressor 100 according to Embodiment 2, the first coating layer 160 a including the solid lubricant 162 with a smaller average particle diameter is placed in a location that is closer to the suction valve seat 141 (base member), while the second coating layer 160 b including the solid lubricant 162 with a larger average particle diameter is placed in a location that is closer to the suction valve 120.
In this configuration, the synthetic resin 161 of the second coating layer 160 b abrades away, and thereby the solid lubricant 162 is exposed on the outer surface of the surface treatment film 160 (second coating layer 160 b) at an earlier time. This allows the solid lubricant 162 with a high stiffness to mitigate the impact force effectively. In addition, since the first coating layer 160 a is elastically deformed to mitigate the impact force effectively, a contact surface pressure can be mitigated significantly.
Because of the above, the compressor 100 according to Embodiment 2 is able to mitigate the impact force more effectively than the compressor 100 according to Embodiment 1. Since the compressor 100 according to Embodiment 2 is able to mitigate the impact force more effectively, it becomes possible to more effectively lessen a noise generated when the suction valve 120 and the suction valve seat 141 collide with each other and more effectively reduce a noise, than the compressor 100 according to Embodiment 1. Moreover, since the compressor 100 according to Embodiment 2 is able to mitigate the impact force more effectively, damages to the suction valve 120 such as break or crack can be lessened, and the performance of the compressor 100 can be maintained for a longer period of time, as compared to the compressor 100 according to Embodiment 1.
Since the solid lubricant 162 is exposed on the outer surface of the surface treatment film 160 (second coating layer 160 b) at an earlier time, the concave-convex portions formed on the outer surface of the surface treatment film 160 vanish at an earlier stage, so that the outer surface of the surface treatment film 160 can be made smooth. Therefore, the seal performance for the suction valve seat 141 and the suction valve 120 can be improved.
Since the solid lubricant 162 with a lipophilic property is exposed on the outer surface of the surface treatment film 160 (second coating layer 160 b) at an earlier time, the lubricating oil 102 with a sufficient amount can stay between the suction valve seat 141 and the suction valve 120. This can improve the seal performance for the suction valve seat 141 and the suction valve 120, and hence suppress the back-flow of the refrigerant 103 during the compression stroke and the discharge stroke.
Since the solid lubricant 162 included in the first coating layer 160 a has a smaller average particle diameter, it has a sufficient adhesion force (binder performance) with respect to the suction valve seat 141. This makes it possible to suppress separation between the surface treatment film 160 (first coating layer 160 a) and the suction valve seat 141, and separation between the first coating layer 160 a and the second coating layer 160 b. Therefore, the compressor 100 according to Embodiment 2 is allowed to have a durability for a longer period of time than the compressor 100 according to Embodiment 1.
In the compressor 100 according to Embodiment 2, the first coating layer 160 a including the solid lubricant 162 with a smaller average particle diameter is placed in a location that is closer to the suction valve seat 141 (base member). For this reason, the synthetic resin 161 easily flows into many vacancies present in the suction vale seat 141. This can more effectively lessen the leakage of the refrigerant 103 from the suction vale seat 141, and therefore suppress reduction of the efficiency of the compressor 100 more effectively.

Modified Example 1

Next, the modified example of the compressor (contact member) according to Embodiment 2 will be described.
In the contact member according to Modified example 1 of Embodiment 2, the solid lubricant of the coating layer located at an inner side, of adjacent coating layers, may be lower in content percentage than the solid lubricant of the coating layer located at an outer side, of the adjacent coating layers.
In the contact member according to Modified example 1 of Embodiment 2, the coating layer located at the inner side, of the adjacent coating layers, may be larger in elastic deformation amount than the coating layer located at the outer side, of the adjacent coating layers.
FIG. 7 is a cross-sectional view of the suction valve seat (contact member) of the compressor according to Modified example 1 of Embodiment 2.
As shown in FIG. 7, the configuration of the surface treatment film 160 provided on the suction valve seat (contact member) of the compressor according to Modified example 1 is basically the same as that of the surface treatment film 160 of the compressor 100 according to Embodiment 2, except that the surface treatment film 160 includes three layers which are the first coating layer 160 a, the second coating layer 160 b, and a third coating layer 160 c.
Specifically, the third coating layer 160 c is placed between the first coating layer 160 a and the second coating layer 160 b. The first coating layer 160 a and the third coating layer 160 c which are adjacent to each other are configured such that the content percentage of the solid lubricant 162 in the first coating layer 160 a is lower than the content percentage of the solid lubricant 162 in the third coating layer 160 c. Also, the third coating layer 160 c and the second coating layer 160 b which are adjacent to each other are configured such that the content percentage of the solid lubricant 162 in the third coating layer 160 c is lower than the content percentage of the solid lubricant 162 in the second coating layer 160 b.
In this configuration, the elastic deformation amount of the first coating layer 160 a can be made larger than the elastic deformation amount of the third coating layer 160 c. In addition, the elastic deformation amount of the third coating layer 160 c can be made larger than the elastic deformation amount of the second coating layer 160 b.
The compressor 100 according to Modified example 1 configured as described above can achieve the same advantages as those of the compressor 100 according to Embodiment 2. Although in the compressor 100 according to Modified example 1, the surface treatment film 160 includes the three coating layers, the present invention is not limited to this, so long as the surface treatment film 160 includes a plurality of coating layers. For example, the surface treatment film 160 may include four coating layers, or ten or more coating layers.

Embodiment 3

A compressor according to Embodiment 3 comprises a cylinder which accommodates a reciprocatable piston therein; a valve plate placed at an opening end of the cylinder and includes a discharge valve seat provided to surround a discharge hole; and a discharge valve which opens and closes the discharge hole, wherein at least one of the discharge valve seat and a portion of the discharge valve which portion contacts the discharge valve seat is provided with a surface treatment film including synthetic resin.
Except for the above feature, the compressor according to Embodiment 3 may be configured as in the compressor according to Embodiment 1 or Embodiment 2.
Now, as an exemplary compressor according to Embodiment 3, the compressor comprising the surface treatment film provided on the discharge valve seat will be described with reference to FIGS. 8 and 9.
FIG. 8 is a cross-sectional view of the major components of a compressor according to Embodiment 3. FIG. 9 is an enlarged cross-sectional view of B-part of FIG. 8.
As shown in FIGS. 8 and 9, the configuration of the compressor 100 according to Embodiment 3 is basically the same as that of the compressor 100 according to Embodiment 1, except that the surface treatment film 160 is provided on the discharge valve seat 142 (to be precise, the surface of the discharge valve seat 142 of the valve plate 117). The configuration and manufacturing method of the surface treatment film 160 are the same as those of the surface treatment film 160 of the compressor 100 according to Embodiment 1, and therefore will not be described in detail repeatedly.
In the compressor 100 according to Embodiment 3 configured as described above, the surface treatment film 160 including the synthetic resin 161 can seal many vacancies which are unique to a sintered metal material and are present in the discharge valve seat 142. Therefore, the leakage of the refrigerant 103 from the discharge valve seat 142 can be reduced. As a result, reduction of the efficiency of the compressor 100 can be suppressed.
In the compressor 100 according to Embodiment 3, since the discharge valve seat 142 is provided with the surface treatment film 160 including the synthetic resin 161, the seal performance for the discharge valve seat 142 and the discharge valve 121 can be improved. As a result, it becomes possible to suppress the back-flow of the refrigerant 103 during the suction stroke.
Therefore, the compressor 100 according to Embodiment 3 can suppress reduction of a refrigeration capability, reduce cost, and increase the efficiency.
In the compressor 100 according to Embodiment 3, since the discharge valve seat 142 is provided with the surface treatment film 160 including the synthetic resin 161, the surface treatment film 160 is able to elastically reduce a hit force generated when the discharge valve 121 closes the discharge valve seat 142. Therefore, a hit noise can be reduced, and the compressor with a low noise can be realized.
Since the hit force generated when the discharge valve 121 closes the discharge valve seat 142 can be reduced, damages to the discharge valve 121 such as break or crack can be lessened. As a result, the performance of the compressor 100 can be maintained for a long period of time.
In the compressor 100 according to Embodiment 3, since the surface treatment film 160 includes the solid lubricant 162 with a lipophilic property, the lubricating oil 102 with a sufficient amount can stay between the discharge valve seat 142 (to be precise, the surface treatment film 160 provided on the surface of the discharge valve seat 142) and the discharge valve 121. This can improve the seal performance for the discharge valve seat 142 and the discharge valve 121, and hence suppress the back-flow of the refrigerant 103 during the compression stroke and the discharge stroke.
In the compressor 100 according to Embodiment 3, since the surface treatment film 160 includes the solid lubricant 162, a shear force generated when the discharge valve 121 closes the discharge valve seat 142 can be reduced because of the lubrication of the solid lubricant 162. This can suppress separation between the surface (outer surface) of the discharge valve seat 142 and the inner surface of the surface treatment film 160. As a result, it becomes possible to realize the compressor 100 with a high durability which can withstand long-time use.
In the compressor 100 according to Embodiment 3, the surface treatment film 160 includes solid lubricant 162. When the compressor 100 is operated, the concave-convex portions formed on the outer surface of the surface treatment film 160 vanish at an earlier time, so that the outer surface of the surface treatment film 160 can be made smooth. Therefore, the seal performance for the discharge valve seat 142 and the discharge valve 121 can be improved.
Although the compressor 100 according to Embodiment 3 is a reciprocating compressor, the present invention is not limited to this, and may be any one of various kinds of compressors such as a rotary compressor or a scroll compressor.

Embodiment 4

A contact member according to Embodiment 4 comprises a surface treatment film including two or more coating layers stacked together, in at least a portion of a contact surface thereof, each of the coating layers includes synthetic resin and a solid lubricant, and the solid lubricant of the coating layer located at an innermost side is lower in content percentage than the solid lubricant of the coating layer located at an outermost side.
A contact member according to Embodiment 4 comprises a surface treatment film including two or more coating layers stacked together, in at least a portion of a contact surface thereof, each of the coating layers includes synthetic resin, and the coating layer located at the innermost side is larger in elastic deformation amount than the coating layer located at the outermost side.
A compressor according to Embodiment 4 comprises a cylinder which accommodates a reciprocatable piston therein; a valve plate placed at an opening end of the cylinder and includes a discharge valve seat provided to surround a discharge hole; and a discharge valve which opens and closes the discharge hole, wherein at least one of the discharge valve seat and the discharge valve comprises the above contact member.
Except for the above feature, the compressor according to Embodiment 4 may be configured as in the compressor according to Embodiment 1 or Embodiment 2.
Now, as an exemplary contact member according to Embodiment 4, a case where the contact member is the discharge valve seat will be described with reference to FIGS. 10 and 11. The configuration of the compressor 100 according to Embodiment 4 is the same as that of the compressor 100 according to Embodiment 1, except for the configuration of the surface treatment film provided on the discharge valve seat. Therefore, the configuration of the compressor 100 according to Embodiment 4 will not be described in detail repeatedly.
FIG. 10 is a cross-sectional view of the major components of a compressor according to Embodiment 4. FIG. 11 is a cross-sectional view of a discharge valve seat (contact member) of the compressor according to Embodiment 4.
As shown in FIGS. 10 and 11, the configuration of the surface treatment film 160 provided on the discharge valve seat (contact member) of the compressor 100 according to Embodiment 4 is basically the same as that of the surface treatment film 160 of the compressor 100 according to Embodiment 3, except that the surface treatment film 160 has a two-layer structure including a first coating layer 160 a and a second coating layer 160 b. The configuration of the surface treatment film 160 (first coating layer 160 a and second coating layer 160 b) of Embodiment 4 is the same as that of the surface treatment film 160 (first coating layer 160 a and second coating layer 160 b) of Embodiment 2, and therefore will not be described in detail repeatedly.
In the compressor 100 according to Embodiment 4 configured as described above, the first coating layer 160 a including the solid lubricant 162 with a smaller average particle diameter is placed in a location that is closer to the discharge valve seat 142 (base member), while the second coating layer 160 b including the solid lubricant 162 with a larger average particle diameter is placed in a location that is closer to the discharge valve 121.
In this configuration, the synthetic resin 161 of the second coating layer 160 b abrades away, and thereby the solid lubricant 162 is exposed on the outer surface of the surface treatment film 160 (second coating layer 160 b) at an earlier time. This can mitigate the impact force effectively. In addition, since the first coating layer 160 a is elastically deformed to mitigate the impact force effectively, a contact surface pressure can be mitigated significantly.
Because of the above, the compressor 100 according to Embodiment 4 is able to mitigate the impact force more effectively than the compressor 100 according to Embodiment 3. Since the compressor 100 according to Embodiment 4 is able to mitigate the impact force more effectively, it becomes possible to more effectively lessen a noise generated when the discharge valve 121 and the discharge valve seat 142 collide with each other and more effectively reduce a noise, than the compressor 100 according to Embodiment 3. Moreover, since the compressor 100 according to Embodiment 4 is able to mitigate the impact force more effectively, damages to the discharge valve 121 such as break or crack can be lessened, and the performance of the compressor 100 can be maintained for a long period of time, as compared to the compressor 100 according to Embodiment 3.
Since the solid lubricant 162 is exposed on the outer surface of the surface treatment film 160 (second coating layer 160 b) at an earlier time, the concave-convex portions provided on the outer surface of the surface treatment film 160 vanish at an earlier time, so that the outer surface of the surface treatment film 160 can be made smooth. Therefore, the seal performance for the discharge valve seat 142 and the discharge valve 121 can be improved.
Since the solid lubricant 162 with a lipophilic property is exposed on the outer surface of the surface treatment film 160 (second coating layer 160 b) at an earlier time, the lubricating oil 102 with a sufficient amount can stay between the discharge valve seat 142 and the discharge valve 121. This can improve the seal performance for the discharge valve seat 142 and the discharge valve 121, and hence suppress the back-flow of the refrigerant 103 during the compression stroke and the discharge stroke.
Since the solid lubricant 162 included in the first coating layer 160 a has a smaller average particle diameter, it has a sufficient adhesion force (binder performance) with respect to the discharge valve seat 142. This makes it possible to suppress separation between the surface treatment film 160 (first coating layer 160 a) and the discharge valve seat 142, and separation between the first coating layer 160 a and the second coating layer 160 b. Therefore, the compressor 100 according to Embodiment 4 is allowed to have a durability for a longer period of time than the compressor 100 according to Embodiment 3.
In the compressor 100 according to Embodiment 4, the first coating layer 160 a including the solid lubricant 162 with a smaller average particle diameter is placed in a location that is closer to the discharge valve seat 142 (base member). For this reason, the synthetic resin 161 easily flows into many vacancies present in the discharge vale seat 142. This can more effectively lessen the leakage of the refrigerant 103 from the discharge vale seat 142, and therefore suppress reduction of the efficiency of the compressor 100 more effectively.
Although in the compressor 100 according to Embodiment 4, the surface treatment film 160 includes the two coating layers, the present invention is not limited to this. For example, the surface treatment film 160 may include three or more coating layers.

Embodiment 5

A compressor according to Embodiment 5 comprises a cylinder which accommodates a reciprocatable piston therein; a valve plate placed at an opening end of the cylinder and includes a suction valve seat provided to surround a suction hole; and a suction valve which opens and closes the suction hole, wherein at least one of the suction valve seat and a portion of the suction valve which portion contacts the suction valve seat is provided with a surface treatment film including synthetic resin.
Except for the above feature, the compressor according to Embodiment 5 may be configured as in the compressor according to any one of Embodiment 1 to Embodiment 4.
Now, as an exemplary compressor according to Embodiment 5, the compressor comprising the surface treatment film provided on a portion of the suction valve which portion contacts the suction valve seat will be described with reference to FIGS. 12 and 13.
FIG. 12 is a cross-sectional view of the major components of the compressor according to Embodiment 5. FIG. 13 is a plan view of the suction valve of FIG. 12. In FIG. 13, the portion of the surface treatment film and the suction valve, which portion contacts the suction valve seat is hatched.
As shown in FIGS. 12 and 13, the configuration of the compressor 100 according to Embodiment 5 is basically the same as that of the compressor 100 according to Embodiment 1, except that the surface treatment film 160 is provided on the suction valve 120. Specifically, the surface treatment film 160 includes a ring-shaped contact portion 163 of the suction valve 120 which contacts the suction vale seat 141.
In Embodiment 5, the surface treatment film 160 has a circular shape with a diameter which is larger than the diameter of the outer periphery of the contact portion 163. The configuration and manufacturing method of the surface treatment film 160 are the same as those of the surface treatment film 160 of the compressor 100 according to Embodiment 1, and therefore will not be described in detail repeatedly.
The compressor 100 according to Embodiment 5 configured as described above can achieve the same advantages as those of the compressor 100 according to Embodiment 1.
In addition, in the compressor 100 according to Embodiment 5, the circular surface treatment film 160 is provided on the suction valve 120 of a flat plate shape. Therefore, the surface treatment film 160 can be formed more uniformly and the productivity of the compressor 100 can be made higher than in a case where the surface treatment film 160 is provided on the suction vale seat 141 of a ring shape.
Although in Embodiment 5, the surface treatment film 160 is provided in the vicinity of the contact portion 163 of the suction valve 120, it may be provided on the entire main surface of the suction valve 120. In this case, also, the same advantages can be achieved.

Embodiment 6

A contact member according to Embodiment 6 comprises a surface treatment film including two or more coating layers stacked together, in at least a portion of a contact surface thereof, each of the coating layers includes synthetic resin and a solid lubricant, and the solid lubricant of the coating layer located at an innermost side is lower in content percentage than the solid lubricant of the coating layer located at an outermost side.
A contact member according to Embodiment 6 comprises a surface treatment film including two or more coating layers stacked together, in at least a portion of a contact surface thereof, each of the coating layers includes synthetic resin, and the coating layer located at the innermost side is larger in elastic deformation amount than the coating layer located at the outermost side.
A compressor according to Embodiment 6 comprises a cylinder which accommodates a reciprocatable piston therein; a valve plate placed at an opening end of the cylinder and includes a suction hole, a suction valve seat provided to surround the suction hole, a discharge hole, and a discharge valve seat provided to surround the discharge hole, a suction valve which opens and closes the suction hole, and a discharge valve which opens and closes the discharge hole, wherein at least one of the suction valve seat, the discharge valve seat, the suction valve, and the discharge valve comprises the contact member.
Except for the above feature, the compressor according to Embodiment 6 may be configured as in the compressor according to any one of Embodiment 1 or Embodiment 4.
Now, as an exemplary contact member according to Embodiment 6, a case where the contact member is the suction valve will be described with reference to FIG. 14. The configuration of the compressor 100 according to Embodiment 6 is the same as that of the compressor 100 according to Embodiment 1, except for the configuration of the surface treatment film provided on the suction valve. Therefore, the configuration of the compressor 100 according to Embodiment 6 will not be described in detail repeatedly.
FIG. 14 is a cross-sectional view of a suction valve (contact member) of a compressor according to Embodiment 6.
As shown in FIG. 14, the configuration of the surface treatment film 160 provided on the suction valve (contact member) of the compressor 100 according to Embodiment 6 is basically the same as that of the surface treatment film 160 of the compressor 100 according to Embodiment 5, except that the surface treatment film 160 has a two-layer structure including a first coating layer 160 a and a second coating layer 160 b. The configuration of the surface treatment film 160 (first coating layer 160 a and second coating layer 160 b) of Embodiment 6 is the same as that of the surface treatment film 160 (first coating layer 160 a and second coating layer 160 b) of Embodiment 2, and therefore will not be described in detail repeatedly.
The compressor 100 according to Embodiment 6 configured as described above can achieve the same advantages as those of the compressor 100 according to Embodiment 2. Although in the compressor 100 according to Embodiment 6, the surface treatment film 160 includes the two coating layers, the present invention is not limited to this. For example, the surface treatment film 160 may include three or more coating layers.

Embodiment 7

A compressor according to Embodiment 7 comprises a cylinder which accommodates a reciprocatable piston therein; a valve plate placed at an opening end of the cylinder and includes a discharge valve seat provided to surround a discharge hole; and a discharge valve which opens and closes the discharge hole, wherein at least one of the discharge valve seat and a portion of the discharge valve which portion contacts the discharge valve seat is provided with a surface treatment film including synthetic resin.
Except for the above feature, the compressor according to Embodiment 7 may be configured as in the compressor according to any one of Embodiment 1 to Embodiment 6.
Now, as an exemplary compressor according to Embodiment 7, the compressor comprising the surface treatment film provided on the portion of the discharge valve which contacts the discharge valve seat will be described with reference to FIGS. 15 and 16.
FIG. 15 is a cross-sectional view of the major components of the compressor according to Embodiment 7. FIG. 16 is a plan view of the discharge valve of FIG. 15. In FIG. 16, the portion of the surface treatment film and the discharge valve, which portion contacts the discharge valve seat is hatched.
As shown in FIGS. 15 and 16, the configuration of the compressor 100 according to Embodiment 7 is basically the same as that of the compressor 100 according to Embodiment 1, except that the surface treatment film 160 is provided on the discharge valve 121. Specifically, the surface treatment film 160 includes a ring-shaped contact portion 164 of the discharge valve 121 which portion contacts the discharge vale seat 142.
In Embodiment 7, the surface treatment film 160 has a circular shape with a diameter which is larger than that of the outer periphery of the contact portion 164. The configuration and manufacturing method of the surface treatment film 160 of the present embodiment are the same as those of the surface treatment film 160 of the compressor 100 according to Embodiment 1, and therefore will not be described in detail repeatedly.
The compressor 100 according to Embodiment 7 configured as described above can achieve the same advantages as those of the compressor 100 according to Embodiment 3.
In addition, in the compressor 100 according to Embodiment 7, the circular surface treatment film 160 is provided on the discharge valve 121 of a flat plate shape. Therefore, the surface treatment film 160 can be formed more uniformly and the productivity of the compressor 100 can be made higher than in a case where the surface treatment film 160 is provided on the discharge vale seat 142 of a ring shape.
Although in Embodiment 7, the surface treatment film 160 is provided in the vicinity of the contact portion 163 of the discharge valve 121, it may be provided on the entire main surface of the discharge valve 121.

Embodiment 8

A contact member according to Embodiment 8 comprises a surface treatment film including two or more coating layers stacked together, in at least a portion of a contact surface thereof, each of the coating layers includes synthetic resin and a solid lubricant, and the solid lubricant of the coating layer located at an innermost side is lower in content percentage than the solid lubricant of the coating layer located at an outermost side.
A contact member according to Embodiment 8 comprises a surface treatment film including two or more coating layers stacked together, in at least a portion of a contact surface thereof, each of the coating layers includes synthetic resin, and the coating layer located at the innermost side is larger in elastic deformation amount than the coating layer located at the outermost side.
A compressor according to Embodiment 8 comprises a cylinder which accommodates a reciprocatable piston therein; a valve plate placed at an opening end of the cylinder and includes a suction hole, a suction valve seat provided to surround the suction hole, a discharge hole, and a discharge valve seat provided to surround the discharge hole, a suction valve which opens and closes the suction hole, and a discharge valve which opens and closes the discharge hole, wherein at least one of the suction valve seat, the discharge valve seat, the suction valve, and the discharge valve comprises the above contact member.
Except for the above feature, the compressor according to Embodiment 8 may be configured as in the compressor according to any one of Embodiment 1 to Embodiment 6.
Now, as an exemplary contact member according to Embodiment 8, a case where the contact member is the discharge valve will be described with reference to FIG. 17. The configuration of the compressor 100 according to Embodiment 8 is the same as that of the compressor 100 according to Embodiment 1, except for the configuration of the surface treatment film provided on the suction valve, and therefore will not be described in detail repeatedly.
FIG. 17 is a cross-sectional view of the discharge valve (contact member) of the compressor according to Embodiment 8.
As shown in FIG. 17, the configuration of the surface treatment film 160 provided on the discharge valve 121 of the compressor 100 according to Embodiment 8 is basically the same as that of the surface treatment film 160 of the compressor 100 according to Embodiment 7, except that the surface treatment film 160 has a two-layer structure including a first coating layer 160 a and a second coating layer 160 b. The configuration of the surface treatment film 160 (first coating layer 160 a and second coating layer 160 b) of Embodiment 8 is the same as that of the surface treatment film 160 (first coating layer 160 a and second coating layer 160 b) of Embodiment 2, and therefore will not be described in detail repeatedly.
The compressor 100 according to Embodiment 8 configured as described above can achieve the same advantages as those of the compressor 100 according to Embodiment 4. Although in the compressor 100 according to Embodiment 8, the surface treatment film 160 includes the two coating layers, the present invention is not limited to this. For example, the surface treatment film 160 may include three or more coating layers.

Embodiment 9

A contact member according to Embodiment 9 comprises a surface treatment film including two or more coating layers stacked together, in at least a portion of a contact surface thereof, each of the coating layers includes synthetic resin and a solid lubricant, and the solid lubricant of the coating layer located at an innermost side is lower in content percentage than the solid lubricant of the coating layer located at an outermost side.
A contact member according to Embodiment 9 comprises a surface treatment film including two or more coating layers stacked together, in at least a portion of a contact surface thereof, each of the coating layers includes synthetic resin, and the coating layer located at the innermost side is larger in elastic deformation amount than the coating layer located at the outermost side.
A compressor according to Embodiment 9 comprises a cylinder which accommodates a reciprocatable piston therein; a valve plate placed at an opening end of the cylinder and includes a suction hole, a suction valve seat provided to surround the suction hole, a discharge hole, and a discharge valve seat provided to surround the discharge hole, a suction valve which opens and closes the suction hole, and a discharge valve which opens and closes the discharge hole, wherein each of the suction valve seat and the suction valve comprises the above contact member.
A compressor according to Embodiment 9 comprises a cylinder which accommodates a reciprocatable piston therein; a valve plate placed at an opening end of the cylinder and includes a suction hole, a suction valve seat provided to surround the suction hole, a discharge hole, and a discharge valve seat provided to surround the discharge hole, a suction valve which opens and closes the suction hole, and a discharge valve which opens and closes the discharge hole, wherein each of the suction valve seat and the suction valve is provided with a surface treatment film including synthetic resin.
Except for the above feature, the compressor according to Embodiment 9 may be configured as in the compressor according to any one of Embodiment 1 to Embodiment 8.
Now, as an exemplary contact member according to Embodiment 9, a case where the contact member is the suction valve seat and the suction valve will be described with reference to FIG. 18. The configuration of the compressor 100 according to Embodiment 9 is the same as that of the compressor 100 according to Embodiment 1, except for the configuration of the surface treatment film provided on the suction valve, and therefore will not be described in detail repeatedly.
FIG. 18 is a cross-sectional view of the major components of the compressor according to Embodiment 9.
As shown in FIG. 18, the configuration of the compressor 100 according to Embodiment 9 is basically the same as that of the compressor 100 according to Embodiment 1, except that the surface treatment film 160 is provided on each of the suction valve seat 141 and the suction valve 120.
The surface treatment film 160 provided on the suction valve seat 141 may include a single coating layer as in the surface treatment film 160 of Embodiment 1, or a plurality of coating layers as in the surface treatment film 160 of Embodiment 2 (including Modified example 1). In the same manner, the surface treatment film 160 provided on the suction valve 120 may include a single coating layer as in the surface treatment film 160 of Embodiment 5, or a plurality of coating layers as in the surface treatment film 160 of Embodiment 6.
When the surface treatment film 160 provided on each of the suction valve seat 141 and the suction valve 120 includes a single coating layer, the solid lubricant 162 included in the surface treatment film 160 provided on one of the suction valve seat 141 and the suction valve 120 may be lower in content percentage than the solid lubricant 162 included in the surface treatment film 160 provided on the other of the suction valve seat 141 and the suction valve 120.
The compressor 100 according to Embodiment 9 configured as described above can achieve the same advantages as those of the compressor 100 according to Embodiment 1, 2, 5 or 6.

Embodiment 10

A contact member according to Embodiment 10 comprises a surface treatment film including two or more coating layers stacked together, in at least a portion of a contact surface thereof, each of the coating layers includes synthetic resin and a solid lubricant, and the solid lubricant of the coating layer located at an innermost side is lower in content percentage than the solid lubricant of the coating layer located at an outermost side.
A contact member according to Embodiment 10 comprises a surface treatment film including two or more coating layers stacked together, in at least a portion of a contact surface thereof, each of the coating layers includes synthetic resin, and the coating layer located at the innermost side is larger in elastic deformation amount than the coating layer located at the outermost side.
A compressor according to Embodiment 10 comprises a cylinder which accommodates a reciprocatable piston therein; a valve plate placed at an opening end of the cylinder and includes a suction hole, a suction valve seat provided to surround the suction hole, a discharge hole, and a discharge valve seat provided to surround the discharge hole, a suction valve which opens and closes the suction hole, and a discharge valve which opens and closes the discharge hole, wherein each of the discharge valve seat and the discharge valve comprises the above contact member.
A compressor according to Embodiment 10 comprises a cylinder which accommodates a reciprocatable piston therein; a valve plate placed at an opening end of the cylinder and includes a discharge valve seat provided to surround a discharge hole, and a discharge valve which opens and closes the discharge hole, wherein each of the discharge valve seat and the discharge valve is provided with a surface treatment film including synthetic resin.
Except for the above feature, the compressor according to Embodiment 10 may be configured as in the compressor according to any one of Embodiment 1 to Embodiment 9.
Now, as an exemplary contact member according to Embodiment 10, a case where the contact member is the discharge valve seat and the discharge valve will be described with reference to FIG. 20. The configuration of the compressor 100 according to Embodiment 10 is the same as that of the compressor 100 according to Embodiment 1, except for the configuration of the surface treatment film provided on the discharge valve seat and the discharge valve, and therefore will not be described in detail repeatedly.
FIG. 19 is a cross-sectional view of the major components of the compressor according to Embodiment 10.
As shown in FIG. 19, the configuration of the compressor 100 according to Embodiment 10 is basically the same as that of the compressor 100 according to Embodiment 1, except that the surface treatment film 160 is provided on each of the discharge valve seat 142 and the discharge valve 121.
The surface treatment film 160 provided on the discharge valve seat 142 may include a single coating layer as in the surface treatment film 160 of Embodiment 3, or a plurality of coating layers as in the surface treatment film 160 of Embodiment 4. In the same manner, the surface treatment film 160 provided on the discharge valve 121 may include a single coating layer as in the surface treatment film 160 of Embodiment 7, or a plurality of coating layers as in the surface treatment film 160 of Embodiment 8.
When the surface treatment film 160 provided on each of the discharge valve seat 142 and the discharge valve 121 includes a single coating layer, the solid lubricant 162 included in the surface treatment film 160 provided on one of the discharge valve seat 142 and the discharge valve 121 may be lower in content percentage than the solid lubricant 162 included in the surface treatment film 160 provided on the other of the discharge valve seat 142 and the discharge valve 121.
The compressor 100 according to Embodiment 10 configured as described above can achieve the same advantages as those of the compressor 100 according to Embodiment 3, 4, 7 or 8.

Embodiment 11

A slide member according to Embodiment 11 comprises a surface treatment film including two or more coating layers stacked together, in at least a portion of a slide surface thereof, each of the coating layers includes synthetic resin and a solid lubricant, and the solid lubricant of the coating layer located at an innermost side is lower in content percentage than the solid lubricant of the coating layer located at an outermost side.
In the slide member according to Embodiment 11, the solid lubricant may comprise at least one compound selected from a compound group consisting of molybdenum disulfide, graphite, polytetrafluoroethylene resin, and antimony trioxide.
In the slide member according to Embodiment 11, the solid lubricant of the coating layer located at the innermost side may be smaller in average particle diameter than the solid lubricant of the coating layer located at the outermost side.
In the contact member according to Embodiment 11, the solid lubricant of the coating layer located at the innermost side may be smaller in weight than the solid lubricant of the coating layer located at the outermost side.
A slide member according to Embodiment 11 comprises a surface treatment film including two or more coating layers stacked together, in at least a portion of a slide surface thereof, each of the coating layers includes synthetic resin, and the coating layer located at an innermost side is larger in elastic deformation amount than the coating layer located at an outermost side.
In the slide member according to Embodiment 11, the surface treatment film may have a thickness of 1 to 10 μm.
In the slide member according to Embodiment 11, the synthetic resin may comprise at least one resin selected from a resin group consisting of polyamide resin, epoxy resin, and phenol resin.
A compressor according to Embodiment 11 comprises an electric component including a stator and a rotor; a compression component activated by the electric component; and a sealed container in which the electric component and the compression component are accommodated and lubricating oil is stored, wherein the compression component includes a crankshaft including a main shaft and an eccentric shaft; a main bearing supporting the crankshaft such that the crankshaft is rotatable; a cylinder block defining a cylinder; a piston which is reciprocatable inside the cylinder; a piston pin mounted to the piston such that a center axis of the piston pin is parallel to the eccentric shaft; and a connecting rod connecting the eccentric shaft and the piston pin to each other, wherein at least one of members constituting the compression component comprises the above slide member.
A manufacturing method of a compressor according to Embodiment 11 comprises (A) applying a first surface treatment agent including synthetic resin and a solid lubricant to at least a portion of a slide surface to form a first coating layer; and (B) applying onto the first coating layer a second surface treatment agent including a solid lubricant with a larger average particle diameter than that of the solid lubricant of the first surface treatment agent to form a second coating layer.
Now, as an exemplary slide member according to Embodiment 11, a case where the slide member is the main shaft of the crankshaft will be described with reference to FIGS. 20 and 21. The configuration of the compressor according to Embodiment 11 is the same as that of the compressor according to any one of Embodiment 1 to Embodiment 10.
[Configuration of Compressor]
FIG. 20 is a vertical sectional view of the compressor according to Embodiment 11. FIG. 21 is an enlarged cross-sectional view of C-part of FIG. 20.
As shown in FIGS. 20 and 21, the configuration of the compressor 100 according to Embodiment 11 is basically the same as that of the compressor 100 according to Embodiment 1 except that the surface treatment film 160 is provided on the main shaft 111.
Specifically, the main shaft 111 includes a first slide section 180 located at an upper side, a second slide section 182 located at a lower side, and a connecting section 181 located between the first slide section 180 and the second slide section 182. The first slide section 180 and the second slide section 182 are configured to contact a bearing section 123 to so as to form a slide surface, and the surface treatment film 160 is provided on the surface of the first slide section 180 and the surface of the second slide section 182.
The thickness of the surface treatment film 160 may be equal to or larger than 1 μm to improve a sliding capability, or may be equal to or smaller than 10 μm to efficiently manufacture the surface treatment film 160. Or, the thickness of the surface treatment film 160 may be equal to or larger than 3 μm and may be equal to or smaller than 6 μm to improve a sliding capability and efficiently manufacture the surface treatment film 160.
The configuration of the surface treatment film 160 according to Embodiment 11 is the same as that of the surface treatment film 160 according to Embodiment 2, and therefore will not be described in detail repeatedly.
Since the outer diameter of the connecting section 181 is set smaller than that of the diameter of the first slide section 180 and the diameter of the second slide section 182, it does not slide with the bearing section 123. For this reason, in Embodiment 11, the connecting section 181 is not provided with the surface treatment film 160.
The material of the base member of the crankshaft 112 is ferrum casting ductile (FCD), while the material of the block 115 including the bearing section 123 is gray cast iron (FC). In Embodiment 11, the surface treatment film 160 is not provided on the slide surface (inner peripheral surface) of the bearing section 123.
By using the compressor 100 according to Embodiment 11 configured as described above, a reliability test was conducted under conditions including a mode in which it was assumed that the main shaft 111 was sliding in contact with local regions of the upper end portion and lower end portion of the bearing section 123, i.e., in a partial contact state. As a result, the compressor 100 according to Embodiment 11 had a good abrasion characteristic as compared to the conventional compressor. The present inventors estimated that such a result was obtained for the reasons described below.
FIG. 22 is a schematic view showing the major components of the compressor in a state in which the main shaft is sliding in the state of partial contact with the bearing section.
As shown in FIG. 22, typically, in the reciprocating compressor, the pressure in the interior of the sealed container 101 is lower than the compression pressure P in the interior of the compression chamber 113 defined by the cylinder 114 and the piston 116, and the main shaft 111 of the crankshaft 112 is partially supported on the eccentric shaft 110 to which the compression load P is applied, in a cantilever manner, by one bearing section 123.
As discussed in Literature (JSME annual meeting Vol. 5-1 (2005) P. 143) of Ito et at., the crankshaft 112 is whirling in an inclined state inside the bearing section 123, due to the compression load P. By comparison, in most cases, the skirt part (facing the eccentric shaft 110) of the piston 116 tends to be inclined downward (hereinafter, this direction will be expressed as “+” side).
When the piston 116 is present in the vicinity of the top dead center in which the compression load P is high and the effect on a sliding loss is significant, the piston 116 is inclined to a large degree to + side, and the crankshaft 112 is inclined inside the bearing section 123 to a largest degree. At this time, a force component P1 of the compression load P at a point at which the upper end of the bearing section 123 and the upper end of the main shaft 111 (first slide section 180) contact each other is largest, and a compression load P2 at a point at which the lower end of the bearing section 123 and the lower end of the main shaft 111 (second slide section 182) contact each other is largest.
Therefore, in a case where the surface treatment film including the solid lubricant with a larger average particle diameter is provided substantially uniformly on the slide surface of the main shaft 111 or the like, the upper end of the bearing section 123 and the upper end of the main shaft 111, contact each other at a point, and the lower end of the bearing section 123 and the lower end of the main shaft 111, contact each other at a point, which increase a surface pressure. For this reason, shifting to steady abrasion occurs early. However, the average particle diameter of the solid lubricant is large, and therefore, a friction coefficient is increased. As a result, it is sometimes difficult to increase the efficiency of the compressor.
In a case where a solid lubricant coating film with a small elastic deformation amount is provided substantially uniformly on the slide surface of the main shaft 111 or the like, the upper end of the bearing section 123 and the upper end of the main shaft 111, contact each other at a point, and the lower end of the bearing section 123 and the lower end of the main shaft 111, contact each other at a point, which increase a surface pressure. For this reason, the solid lubricant coating film is likely to abrade early, or be separated.
On the other hand, in a case where the surface treatment film including the solid lubricant with a smaller average particle diameter is provided substantially uniformly on the slide surface of the main shaft 111 or the like, the abrasion resistance of the solid lubricant of the surface treatment film is low. For this reason, a long time passes until shifting to the steady abrasion occurs and the efficiency of the compressor is increased. Or, the synthetic resin abrades away before shifting to the steady abrasion occurs, and thus the efficiency of sliding cannot be sufficiently increased for a long period of time.
In a case where a solid lubricant coating film with a larger elastic deformation amount is provided on the slide surface of the main shaft 111 or the like, the mechanical strength of the solid lubricant coating film is low. Therefore, a high performance cannot be ensured for a long period of time.
However, in the compressor 100 according to Embodiment 1, even when local-contact sliding occurs, the convex portion of the surface of the solid lubricant 162 with a larger average particle diameter, included in the second coating layer 160 b located at an outer side, abrades away, so that the slide surface which is smooth and has a suitable oil sump, i.e., early compatibility surface is formed and shifting to the steady abrasion can take place, at an earlier time.
Thereafter, the second coating layer 160 b abrades away, and the first coating layer 160 a is exposed as the outer surface. Since the first coating layer 160 a includes the solid lubricant 162 with a smaller friction coefficient and a smaller average particle diameter, sliding with low friction and high efficiency can be performed. Because of this, the compressor 100 according to Embodiment 11 is allowed to shift to a steady abrasion state at an earlier time, and thereafter perform an operation with high efficiency while providing a good abrasion characteristic.
In the compressor 100 according to Embodiment 11, even when local-contact sliding occurs, the first coating layer 160 a located closer to the base member (inner side) is elastically deformed around a contact point, to perform a buffering effect. This can mitigate a contact surface pressure significantly. In addition, the solid lubricant 162 included in the second coating layer 160 b located at the outer side allows the surface treatment film 160 to have high strength and high abrasion resistance with respect to sliding. Thereby, early abrasion and separation of the surface treatment film 160 can be suppressed, and a good friction/abrasion characteristic can be obtained.
In the compressor 100 according to Embodiment 1, the first coating layer 160 a including the solid lubricant 162 with a smaller average particle diameter is placed in a location that is closer to the base member. Therefore, the solid lubricant 162 easily enters concave portions of the minute concave-convex portions which are formed on the surface of the main shaft 111. Even if the abrasion of the solid lubricant 162 located in a region of the first coating layer 160 a that is closer to the outer surface progresses, the solid lubricant 162 with a large amount is left in a region that is closer to the base member. Therefore, the solid lubricant 162 works for a long period of time.
Although in the present embodiment, the sliding motion in the partial contact state has been described, it is obvious that higher reliability and higher efficiency can be expected in a non-partial contact state.
Although in the present embodiment, the surface treatment film 160 is provided on the first slide section 180 and the second slide section 182 of the main shaft 111 which are more likely to partially contact the bearing section 123, the present invention is not limited to this. For example, instead of providing the surface treatment film 160 on the main shaft 111, the surface treatment film 160 may be provided on the slide surface of the bearing section 123, or on both of the main shaft 111 and the bearing section 123.
Or, for example, the surface treatment film 160 may be provided on the slide surface of at least one of the piston 116 and the cylinder 114 which are assumed to slide in a partial contact state, due to the compression load P. In this case, to increase a productivity, the surface treatment film 160 may be provided on the slide surface of the piston 116, or on the outer peripheral portion of the top side (facing the compression chamber 113) of the piston 116 and the outer peripheral portion of the skirt side (facing the eccentric shaft 110) of the piston 116.

Modified Example 1

Next, modified example of the compressor (slide member) according to Embodiment 11 will be described.
In a slide member according to Modified example 1 of Embodiment 11, the solid lubricant of the coating layer located at an inner side, of adjacent coating layers, is lower in content percentage than the solid lubricant of the coating layer located at an outer side, of the adjacent coating layers.
In the slide member according to Modified example 1 of Embodiment 11, the coating layer located at the inner side, of the adjacent coating layers, may be larger in elastic deformation amount than the coating layer located at the outer side, of the adjacent coating layers.
FIG. 23 is a cross-sectional view of a main shaft (slide member) of the compressor according to Modified example 1 of Embodiment 11.
As shown in FIG. 23, the configuration of the surface treatment film 160 provided on the main shaft (slide member) of the compressor according to Modified example 1 is basically the same as that of the surface treatment film 160 of the compressor 100 according to Embodiment 11, except that the surface treatment film 160 includes three layers which are the first coating layer 160 a, the second coating layer 160 b, and the third coating layer 160 c.
Specifically, the third coating layer 160 c is placed between the first coating layer 160 a and the second coating layer 160 b. The first coating layer 160 a and third coating layer 160 c which are adjacent to each other are configured such that the content percentage of the solid lubricant 162 in the first coating layer 160 a is lower than the content percentage of the solid lubricant 162 in the third coating layer 160 c. Also, the third coating layer 160 c and the second coating layer 160 b which are adjacent to each other are configured such that the content percentage of the solid lubricant 162 in the third coating layer 160 c is lower than the content percentage of the solid lubricant 162 in the second coating layer 160 b.
In this configuration, the elastic deformation amount of the first coating layer 160 a can be made larger than the elastic deformation amount of the third coating layer 160 c. In addition, the elastic deformation amount of the third coating layer 160 c can be made larger than the elastic deformation amount of the second coating layer 160 b.
The compressor 100 according to Modified example 1 configured as described above can achieve the same advantages as those of the compressor 100 according to Embodiment 2.
In the compressor 100 according to Modified example 1, the content percentage (size) of the solid lubricant 162 changes in a stepwise manner from the inner side to the outer side. This enable smooth sifting from initial abrasion to steady abrasion. As a result, the operation with high efficiency can be performed for a longer period of time. Furthermore, since in the compressor 100 according to Modified example 1, the elastic deformation amount of the coating layers changes in a stepwise manner from the inner side to the outer side, the adhesion force between the coating layers can be increased, and the separation of the surface treatment film 160 from the base member can be suppressed more effectively.
Although in the compressor 100 according to Modified example 1, the surface treatment film 160 includes the three coating layers, the present invention is not limited to this, so long as the surface treatment film 160 includes a plurality of coating layers. For example, the surface treatment film 160 may include four coating layers, or ten or more coating layers.

Embodiment 12

A compressor according to Embodiment 12 comprises an electric component including a stator and a rotor; a compression component activated by the electric component; and a sealed container in which the electric component and the compression component are accommodated and lubricating oil is stored, wherein the compression component includes a crankshaft including a main shaft and an eccentric shaft; a main bearing supporting the crankshaft such that the crankshaft is rotatable; a cylinder block defining a cylinder; a piston which is reciprocatable inside the cylinder; a piston pin mounted to the piston such that a center axis of the piston pin is parallel to the eccentric shaft; and a connecting rod connecting the eccentric shaft and the piston pin to each other, wherein a slide portion of at least one of slide members constituting the compression component is provided with a linear surface treatment film surrounding the slide portion.
In the compressor according to Embodiment 12, a plurality of surface treatment films may be placed in parallel.
In the compressor according to Embodiment 12, the surface treatment film may be placed in parallel to a direction perpendicular to the center axis of the main shaft.
In the compressor according to Embodiment 12, the surface treatment film may have a thickness of 1 to 10 μm.
Now, as an exemplary compressor according to Embodiment 12, a case where the slide member is the main shaft of the crankshaft will be described with reference to FIGS. 24 and 25. The configuration of the compressor 100 according to Embodiment 12 may be the same as that of the compressor 100 according to any one of Embodiment 1 to Embodiment 10, except for the above feature.
[Configuration of Compressor]
FIG. 24 is a vertical sectional view of a compressor according to Embodiment 12. FIG. 25 is an enlarged cross-sectional view of D-part of FIG. 24.
As shown in FIGS. 24 and 25, the configuration of the compressor 100 according to Embodiment 12 is basically the same as that of the compressor 100 according to Embodiment 11, except that linear surface treatment films 160 are provided on the first slide section 180 and the second slide section 182 of the main shaft 111.
In Embodiment 12, specifically, the plurality of surface treatment films 160 have a linear shape (ring shape). The plurality of surface treatment films 160 are placed in parallel with each other in the direction perpendicular to the center axis 111 a of the main shaft 111. A recessed groove 165 is provided between adjacent surface treatment films 160.
The length of the surface treatment film 160 in the direction of the center axis 111 a may be set suitably depending on the operation conditions of the compressor 100, etc., and may be, for example, about 1 mm. The length of the recessed groove 165 in the direction of the center axis 111 a may be set suitably depending on the operation conditions of the compressor 100, etc., and may be, for example, about 0.5 μm.
The thickness of the surface treatment film 160 may be equal to or larger than 1 μm to increase the productivity of the surface treatment film 160, and may be equal to or smaller than 10 μm to fill the lubricating oil 102 with a sufficient amount in the recessed groove 165 to improve the sliding characteristic of the surface treatment film 160. Or, the thickness of the surface treatment film 160 may be equal to or larger than 3 μm and equal to or smaller than 6 μm to improve the sliding characteristic of the surface treatment film 160 and efficiently manufacture the surface treatment film 160.
For example, in the vicinity of the upper end of the first slide section 180 which tends to slide in a lubrication region where both of the solid lubricant and the lubricating oil are present, and in the vicinity of the lower end of the second slide section 182 which tends to slide in a lubrication region where both of the solid lubricant and the lubricating oil are present, the width of the recessed groove 165 may be made smaller to increase the area of actual sliding of the surface treatment film 160, to improve an abrasion resistance. In contrast, in the vicinity of the lower end of the first slide section 180 which tends to slide in a lubrication region where the lubricating oil is present, and in the vicinity of the upper end of the second slide section 182 which tends to slide in a lubrication region where the lubricating oil is present, the width of the recessed groove 165 may be made larger to reduce the area of actual sliding of the surface treatment film 160, to reduce a sliding loss.
The surface treatment film 160 may include a single coating layer as in the surface treatment film 160 according to Embodiment 1, or two or more coating layers as in the surface treatment film 160 according to Embodiment 2 (including Modified example 1 of Embodiment 2).
[Manufacturing Method of Surface Treatment Film]
Next, the manufacturing method of the surface treatment film 160 will be described with reference to FIGS. 24 to 27.
FIG. 26 is a schematic view showing the configuration of a pneumatic syringe dispenser device. FIG. 27 is a schematic view showing the outline of manufacturing a surface treatment film, by using the device of FIG. 26.
Initially, the configuration of the pneumatic syringe dispenser device will be described with reference to FIG. 26.
As shown in FIG. 26, the pneumatic syringe dispenser device 300 includes an air source 301, a regulator 302, a discharge timer 303, a controller 304, an electric power supply 305, a syringe 306, and a nozzle 307. The dispenser refers to a fixed-amount liquid discharge system. The dispenser is able to stably supply a coating agent 313 with a target amount and inject and apply liquid droplets of the coating agent 313 in succession to a work (corresponding to the main shaft 111 of the crankshaft 112 in the present embodiment).
Next, the manufacturing method of the surface treatment film 160 will be described with reference to FIGS. 24 to 27.
Initially, preliminary heating is conducted to increase the temperature of the crankshaft 112 up to a predetermined temperature (only a region which is in the vicinity of the first slide section 180 and the second slide section 182 of the main shaft 111 may be heated in this heating). This is intended to cause the coating agent 313 to easily adhere onto the main shaft 111.
Then, prepared is the coating agent 313 with a specified viscosity which is produced by adjusting a liquid agent including the synthetic resin 161 and the solid lubricant 162 dispersed in the synthetic resin 161 with a diluting agent comprising an organic agent. Then, this coating agent 313 is poured into the syringe 306. Then, the crankshaft 112 is rotated in a clockwise direction around the center axis 111 a, and the coating agent 313 is injected and applied with a specified target amount to a particular region at a constant speed and at constant intervals, from the nozzle 307, in a state in which the syringe 306 of the pneumatic syringe dispenser device 300 is fixed.
At a stage in which a single linear surface treatment film 160 has been formed to extend along the outer periphery of the main shaft 111, the injection and application of the coating agent 313 from the nozzle 307 are ceased. The syringe 306 is moved upward (or downward), and the injection and application of the coating agent 313 from the nozzle 307 are performed. At this time, by adjusting the movement amount of the syringe 306, a region to which the coating agent 313 is not applied, i.e., the recessed groove 165 is formed. This is repeated, and thus the plurality of surface treatment films 160 and the recessed grooves 165 (surface treatment film 160 and recessed groove 165 are parallel to each other) can be formed independently on the first slide section 180 and the second slide section 182 of the main shaft 111.
Thereafter, drying is temporarily conducted for several minutes under a temperature which is slightly higher than the temperature in the preliminary heating. At a stage in which the surface of the surface treatment film 160 is cured, buffing is conducted a little in order to finely adjust the surface roughness of the surface treatment film 160. Desirably, a buff used in the buffing is a horse hair buff, rather than a nylon buff containing abrasive grains or a relatively hard steel buff.
Finally, calcining is conducted under a temperature of about 200 degrees C. to 250 degrees C. for about 30 minutes to 2 hours, to vaporize the diluting agent in the coating agent 313. In this way, the surface treatment film 160 is allowed to completely adhere to the first slide section 180 and the second slide section 182.
By using the compressor 100 according to Embodiment 12 manufactured by the above described method, an actual device reliability test was conducted under conditions including a mode in which it was assumed that the main shaft 111 and the bearing section 123 slid relatively in harsh conditions and the lubricating oil 102 with a sufficient amount between the slide members could not be ensured. As a result, the compressor 100 according to Embodiment 12 had a good abrasion characteristic as compared to the conventional compressor. The present inventors estimated that such a result was obtained for the reasons described below.
In some situations, the lubricating oil 102 with a sufficient amount between the main shaft 111 and the bearing section 123 cannot be ensured. Because of the recessed grooves 165 each of which is formed between the surface treatment films 160, the main shaft 111 made of metal is exposed. In this state, due to a surface tension, the lubricating oil 102 is easily filled in the recessed grooves 165. The lubricating oil 102 filled in the recessed grooves 165 moves to the slide portions of the surface treatment films 160 and the slide portion of the bearing section 123, and thereby the lubricating oil 102 can be retained on the slide surfaces well. This can effectively suppress the abrasion of the surface treatment films 160 and ensure a high abrasion resistance.
The compressor 100 according to Embodiment 12 configured as described above can achieve the same advantages as those of the compressor 100 according to Embodiment 11.

Modified Example 1

Next, the modified example of the compressor (contact member) according to Embodiment 12 will be described.
A compressor according to Modified example 1 of Embodiment 12 comprises an electric component including a stator and a rotor; a compression component activated by the electric component; and a sealed container in which the electric component and the compression component are accommodated and lubricating oil is stored, wherein the compression component includes a crankshaft including a main shaft and an eccentric shaft; a main bearing supporting the crankshaft such that the crankshaft is rotatable; a cylinder block defining a cylinder; a piston which is reciprocatable inside the cylinder; a piston pin mounted to the piston such that a center axis of the piston pin is parallel to the eccentric shaft; and a connecting rod connecting the eccentric shaft and the piston pin to each other, wherein a slide portion of at least one of slide members constituting the compression component is provided with a linear surface treatment film surrounding the slide portion.
In the compressor according to Modified example 1 of Embodiment 12, the surface treatment film may be placed in a spiral shape with an upward slope extending in a direction that is opposite to the rotational direction of the crankshaft.
In the compressor according to Modified example 1 of Embodiment 12, the main shaft may be provided on a surface thereof with a spiral groove with an upward slope extending in a direction that is opposite to the rotational direction of the crankshaft, and the surface treatment film may have the inclination angle with respect to the center axis of the main shaft which angle is smaller than the inclination angle of the groove with respect to the center axis of the main shaft.
FIG. 28 is a vertical sectional view of a compressor according to Modified example 1 of Embodiment 12. FIG. 29 is an enlarged cross-sectional view of E-part of FIG. 28.
As shown in FIGS. 28 and 29, the configuration of the compressor 100 according to Modified example 1 of Embodiment 12 is basically the same as that of the compressor 100 according to Embodiment 12, except that the surface treatment film 160 is placed in a spiral shape with an upward slope extending in a direction that is opposite to the rotational direction of the crankshaft 112.
Specifically, the surface treatment film 160 is configured such that the inclination angle with respect to the center axis 111 a of the main shaft 111 is smaller than the inclination angle of the groove 183 of the oil feeding mechanism 151 with respect to the center axis 111 a of the main shaft 111. In other words, the inclination angle of the recessed groove 165 with respect to the center axis 111 a is smaller than the inclination angle of the groove 183 of with respect to the center axis 111 a.
The manufacturing method of the surface treatment film 160 according to Modified example 1 is the same as that of the face treatment film 160 of according to Embodiment 12, and therefore will not be described in detail repeatedly.
By using the compressor 100 according to Modified example 1 configured as described above, an actual device reliability test was conducted under conditions including a mode in which it was assumed that the main shaft 111 and the bearing section 123 slid relatively in harsh conditions and the lubricating oil 102 with a sufficient amount between the slide members could not be ensured. As a result, the compressor 100 according to Modified example 1 had a good abrasion characteristic as compared to the conventional compressor. The present inventors estimated that such a result was obtained for the reasons described below.
In some situations, the lubricating oil 102 with a sufficient amount between the main shaft 111 and the bearing section 123 cannot be ensured. As in the compressor 100 according to Embodiment 12, in the compressor 100 according to Modified example 1, because of the surface tension of the recessed grooves 165 each of which is formed between the surface treatment films 160, the lubricating oil 102 is easily filled in the recessed grooves 165. The lubricating oil 102 filled in the recessed grooves 165 moves to the slide portions of the surface treatment films 160 and the slide portion of the bearing section 123, and thereby the lubricating oil 102 can be retained on the slide surfaces well. This can effectively suppress the abrasion of the surface treatment films 160 and ensure a high abrasion resistance.
It is also estimated that the recessed groove 165 of the spiral shape formed between the surface treatment films 160 serves as an oil pump passage which transports the lubricating oil 102 to the upper side of the main shaft, against a gravitational force. In addition, in Modified example 1, the surface treatment film 160 is configured such that the inclination angle of the recessed groove 165 with respect to the center axis 111 a is smaller than the inclination angle of the groove 183 with respect to the center axis 111 a. Because of this, the recessed groove 165 makes it possible to transport the lubricating oil 102 with a sufficient amount to an upper side even in a low-speed operation mode, and supply the lubricating oil 102 with a sufficient amount to the surface treatment film 160 and the slide surface of the bearing section 123.
The compressor 100 according to Modified example 1 configured as described above can achieve the same advantages as those of the compressor 100 according to Embodiment 12.
In addition, in the compressor 100 according to Modified example 1, during the operation of the compressor 100 in the low-speed operation node by the inverter driving circuit as described above, the lubricating oil 102 can be supplied with a sufficient amount to the surface treatment film 160 and the slide surface of the bearing section 123, and as a result, a good abrasion characteristic can be ensured.
Numerous modifications and alternative embodiments of the invention will be apparent to those skilled in the art in view of the foregoing description. Accordingly, the description is to be construed as illustrative only, and is provided for the purpose of teaching those skilled in the art the best mode of carrying out the invention. The details of the structure and/or function may be varied substantially without departing from the spirit of the invention.

INDUSTRIAL APPLICABILITY

A compressor of the present invention is able to achieve high reliability and high efficiency, and therefore is widely applicable to examples using refrigeration cycles, such as home refrigerators, air conditioners, dehumidification devices, show cases, vending machines, etc.

REFERENCE SIGNS LIST

- 100 compressor
- 101 sealed container
- 102 lubricating oil
- 103 refrigerant
- 104 compressor body
- 105 suspension spring
- 106 electric component
- 107 stator
- 108 rotor
- 109 compression component
- 110 eccentric shaft
- 111 main shaft
- 111 a center axis
- 112 crankshaft
- 113 compression chamber
- 114 cylinder
- 115 block
- 116 piston
- 117 valve plate
- 118 suction plate
- 119 discharge hole
- 120 suction valve
- 120 a opening/closing section
- 121 discharge valve
- 122 connecting means
- 123 bearing section
- 130 spring reed
- 131 valve stop
- 132 recessed portion
- 141 suction valve seat
- 142 discharge valve seat
- 150 suction pipe
- 151 oil feeding mechanism
- 152 cylinder head
- 153 head bolt
- 154 suction muffler
- 156 head space
- 157 discharge pipe
- 160 surface treatment film
- 160 a first coating layer
- 160 b second coating layer
- 160 c third coating layer
- 161 synthetic resin
- 162 solid lubricant
- 163 contact portion
- 164 contact portion
- 165 recessed groove
- 180 first slide section
- 181 connecting section
- 182 second slide section
- 183 groove
- 300 pneumatic syringe dispenser device
- 301 air source
- 302 regulator
- 303 discharge timer
- 304 controller
- 305 electric power supply
- 306 syringe
- 307 nozzle
- 313 coating agent

Claims

1. A compressor comprising:

a cylinder which accommodates a reciprocatable piston therein;

a valve plate placed at an opening end of the cylinder and includes a discharge valve seat provided to surround a discharge hole; and

a discharge valve which opens and closes the discharge hole,

wherein at least one of the discharge valve seat and a portion of the discharge valve which portion contacts the discharge valve seat is provided with a surface treatment film including synthetic resin.

2. A compressor comprising:

a cylinder which accommodates a reciprocatable piston therein;

a valve plate placed at an opening end of the cylinder and includes a suction valve seat provided to surround a suction hole; and

a suction valve which opens and closes the suction hole,

wherein at least one of the suction valve seat and a portion of the suction valve which portion contacts the suction valve seat is provided with a surface treatment film including synthetic resin.

3. The compressor according to claim 1, further comprising:

a suction valve which opens and closes a suction hole,

wherein the valve plate further includes a suction valve seat provided to surround the suction hole, and

4. The compressor according claim 1,

wherein the surface treatment film includes a solid lubricant.

5. The compressor according to claim 1,

wherein each of the discharge valve seat and the portion of the discharge valve which portion contacts the discharge valve seat is provided with the surface treatment film.

6. The compressor according to claim 2,

wherein each of the suction valve seat and the portion of the suction valve which portion contacts the suction valve seat is provided with the surface treatment film.

7. The compressor according to claim 1,

wherein the surface treatment film has a thickness of 1 μm to 20 μm.

8. The compressor according to claim 1,

wherein the synthetic resin comprises at least one resin selected from a resin group consisting of polyamide resin, epoxy resin, and phenol resin.

9. The compressor according to claim 4,

wherein the solid lubricant comprises at least one compound selected from a compound group consisting of molybdenum disulfide, graphite, polytetrafluoroethylene resin, and antimony trioxide.

10. The compressor according claim 2,

wherein the surface treatment film includes a solid lubricant.

11. The compressor according to claim 2,

wherein the surface treatment film has a thickness of 1 μm to 20 μm.

12. The compressor according to claim 2,