U.S. patent application number 14/649457 was filed with the patent office on 2015-10-22 for contact member, slide member, compressor comprising contact member or slide member, and manufacturing method of compressor.
The applicant listed for this patent is PANASONIC CORPORATION. Invention is credited to Hiroyuki FUKUHARA, Yoshiyuki FUTAGAMI, Yoshinori ISHIDA, Hirotaka KAWABATA, Masakazu YAMAOKA.
Application Number | 20150300340 14/649457 |
Document ID | / |
Family ID | 50934060 |
Filed Date | 2015-10-22 |
United States Patent
Application |
20150300340 |
Kind Code |
A1 |
ISHIDA; Yoshinori ; et
al. |
October 22, 2015 |
CONTACT MEMBER, SLIDE MEMBER, COMPRESSOR COMPRISING CONTACT MEMBER
OR SLIDE MEMBER, AND MANUFACTURING METHOD OF COMPRESSOR
Abstract
A contact member or a slide member of the present invention
comprises a surface treatment film (160) including two or more
coating layers stacked together, in at least a portion of a contact
surface or a slide surface thereof, wherein each of the coating
layers includes synthetic resin and a solid lubricant, and wherein
the solid lubricant (162) 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 or a slide member of the present invention comprises
a surface treatment film (160) including two or more coating layers
stacked together, in at least a portion of a contact surface or 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.
Inventors: |
ISHIDA; Yoshinori; (Kyoto,
JP) ; FUTAGAMI; Yoshiyuki; (Shiga, JP) ;
FUKUHARA; Hiroyuki; (Shiga, JP) ; KAWABATA;
Hirotaka; (Shiga, JP) ; YAMAOKA; Masakazu;
(Shiga, JP) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
PANASONIC CORPORATION |
Kadoma-shi, Osaka |
|
JP |
|
|
Family ID: |
50934060 |
Appl. No.: |
14/649457 |
Filed: |
December 11, 2013 |
PCT Filed: |
December 11, 2013 |
PCT NO: |
PCT/JP2013/007290 |
371 Date: |
June 3, 2015 |
Current U.S.
Class: |
417/415 ;
137/855; 184/5; 417/569 |
Current CPC
Class: |
C10M 103/06 20130101;
C10M 107/38 20130101; F04B 39/0292 20130101; F05C 2253/12 20130101;
F05C 2253/20 20130101; C10M 103/02 20130101; F04B 39/0276 20130101;
F04C 18/0207 20130101; C10N 2040/30 20130101; F04C 2230/91
20130101; F04B 39/1073 20130101; C10N 2050/023 20200501; C10N
2050/14 20200501; F04B 39/1066 20130101; F04C 29/128 20130101; F05C
2251/14 20130101; F16K 15/16 20130101; C10M 2201/0663 20130101;
C10M 2201/0623 20130101; C10M 2201/0413 20130101; F04B 35/04
20130101; C10M 2213/0623 20130101; C10M 2201/0623 20130101; C10N
2010/10 20130101; C10M 2201/0623 20130101; C10N 2010/10
20130101 |
International
Class: |
F04B 39/02 20060101
F04B039/02; F04B 35/04 20060101 F04B035/04 |
Foreign Application Data
Date |
Code |
Application Number |
Nov 12, 2012 |
JP |
2012-269995 |
Dec 11, 2012 |
JP |
2012-269989 |
Dec 11, 2012 |
JP |
2012-269990 |
Dec 11, 2012 |
JP |
2012-269991 |
Nov 7, 2013 |
JP |
2013-230936 |
Nov 7, 2013 |
JP |
2013-230937 |
Nov 8, 2013 |
JP |
2013-231874 |
Claims
1. A contact member comprising: a surface treatment film including
two or more coating layers stacked together, in at least a portion
of a contact surface thereof, wherein each of the coating layers
includes synthetic resin and a solid lubricant, and wherein 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.
2. The contact member according to claim 1, wherein 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.
3. The contact member according to claim 1, wherein the solid
lubricant comprises at least one compound selected from a compound
group consisting of molybdenum disulfide, graphite,
polytetrafluoroethylene resin, and antimony trioxide.
4. The contact member according to claim 1, wherein the solid
lubricant of the coating layer located at the innermost side is
smaller in average particle diameter than the solid lubricant of
the coating layer located at the outermost side.
5. A contact member comprising: a surface treatment film including
two or more coating layers stacked together, in at least a portion
of a contact surface thereof, wherein each of the coating layers
includes synthetic resin, and wherein the coating layer located at
an innermost side is larger in elastic deformation amount than the
coating layer located at an outermost side.
6. The contact member according to claim 5, wherein the coating
layer located at an inner side, of adjacent coating layers, is
larger in elastic deformation amount than the coating layer located
at an outer side, of the adjacent coating layers.
7. The contact member according to claim 1, wherein the surface
treatment film has a thickness of 1 .mu.m to 30 .mu.m.
8. The contact member 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. 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 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 as recited in claim 1.
10. A slide member comprising: a surface treatment film including
two or more coating layers stacked together, in at least a portion
of a slide surface thereof, wherein each of the coating layers
includes synthetic resin and a solid lubricant, and wherein 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.
11. The slide member according to claim 10, wherein 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.
12. The slide member according to claim 10, wherein the solid
lubricant comprises at least one compound selected from a compound
group consisting of molybdenum disulfide, graphite,
polytetrafluoroethylene resin, and antimony trioxide.
13. The slide member according to claim 10, wherein the solid
lubricant of the coating layer located at the innermost side is
smaller in average particle diameter than the solid lubricant of
the coating layer located at the outermost side.
14. A slide member comprising: a surface treatment film including
two or more coating layers stacked together, in at least a portion
of a slide surface thereof, wherein each of the coating layers
includes synthetic resin, and wherein the coating layer located at
an innermost side is larger in elastic deformation amount than the
coating layer located at an outermost side.
15. The slide member according to claim 14, wherein the coating
layer located at an inner side, of adjacent coating layers, is
larger in elastic deformation amount than the coating layer located
at an outer side, of the adjacent coating layers.
16. The slide member according to claim 10, wherein the surface
treatment film has a thickness of 1 .mu.m to 10 .mu.m.
17. The slide according to claim 10, wherein the synthetic resin
comprises at least one resin selected from a resin group consisting
of polyamide resin, epoxy resin, and phenol resin.
18. A compressor comprising: 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, and wherein
at least one of members constituting the compression component
comprises the slide member as recited in claim 10.
19. The compressor according to claim 18, wherein a suction
pressure is applied to the lubricating oil stored in the sealed
container.
20. A manufacturing method of a compressor comprising: (A) applying
a first surface treatment agent including synthetic resin and a
solid lubricant to at least a portion of a slide surface or 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 the solid lubricant of the first surface treatment
agent to form a second coating layer.
21. The contact member according to claim 2, wherein the solid
lubricant comprises at least one compound selected from a compound
group consisting of molybdenum disulfide, graphite,
polytetrafluoroethylene resin, and antimony trioxide.
22. The contact member according to claim 5, wherein the surface
treatment film has a thickness of 1 .mu.m to 30 .mu.m.
23. The contact member according to claim 5, wherein the synthetic
resin comprises at least one resin selected from a resin group
consisting of polyamide resin, epoxy resin, and phenol resin.
24. 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 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 as recited in claim 5.
25. The slide member according to claim 11, wherein the solid
lubricant comprises at least one compound selected from a compound
group consisting of molybdenum disulfide, graphite,
polytetrafluoroethylene resin, and antimony trioxide.
26. The slide member according to claim 14, wherein the surface
treatment film has a thickness of 1 .mu.m to 10 .mu.m.
27. The slide according to claim 14, wherein the synthetic resin
comprises at least one resin selected from a resin group consisting
of polyamide resin, epoxy resin, and phenol resin.
28. A compressor comprising: 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, and wherein
at least one of members constituting the compression component
comprises the slide member as recited in claim 14.
29. The compressor according to claim 28, wherein a suction
pressure is applied to the lubricating oil stored in the sealed
container.
Description
TECHNICAL FIELD
[0001] The present invention relates to a contact member, a slide
member, a compressor comprising the contact member or the slide
member, and a manufacturing method of the compressor, which can
improve efficiency and reliability in the compressor which is
primarily used in a home refrigerator.
BACKGROUND ART
[0002] To achieve energy saving of home refrigerators, the
efficiency of a compressor has been increased, because of 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. With the increase in the efficiency
of the compressor, compression components of the compressor have
been forced to slide in harsh conditions.
[0003] An exemplary conventional compressor includes an electric
motor unit, and a compression/mechanical unit activated by the
electric motor unit, in which a solid lubricant is applied as a
synthetic resin agent on the slide surface of a crankshaft included
in the compression/mechanical unit (e.g., see Patent Literature
1).
[0004] Another 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 2).
[0005] 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
[0006] Patent Literature 1: Japanese Laid-Open Patent Application
Publication No. Hei. 2-176195 [0007] Patent Literature 2: Japanese
Laid-Open Patent Application Publication No. 2000-45949
SUMMARY OF INVENTION
Technical Problem
[0008] In a reciprocating compressor, due to a difference between a
pressure in the interior of a compression chamber and a pressure in
the interior of a suction muffler, a suction valve contacts (hits)
a suction valve seat located around a suction hole, and then closes
the suction hole. Repeated hit (collision) between these metal
members causes an accumulated metal fatigue in a portion of the
suction valve and a portion of the suction valve seat which
portions contact each other.
[0009] Also, under the recent circumstances in which higher
efficiency is required to be attained, due to reduction of the
thickness of the suction valve formed of a steel plate and the
changeable speed rotation mode with the use of inverter driving,
the above mentioned metal fatigue is accumulated more and more, and
break or crack tends to occur in the contact portion of the suction
valve. This is a first problem. The same problem arises in a
discharge valve and a discharge valve seat.
[0010] Since the valve plate is made of a sintered metal material,
the valve plate has vacancies which are unique to the sintered
metal material. Due to the leakage of the refrigerant through the
vacancies, in the suction valve seat provided on the valve plate to
surround the suction hole and the discharge valve seat provided on
the valve plate to surround the discharge hole, the efficiency of
the compressor is reduced. This is the second problem.
[0011] If the refrigerant oil (lubricating oil) with a low
viscosity is used to achieve energy saving, the lubricating oil
staying between the suction valve seat and the suction valve or
between the discharge valve seat and the discharge valve is
reduced, and thereby the sealing 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.
[0012] Also, when the suction valve or the discharge valve being
closed hits the suction valve seat or 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 third 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 suction
valve hits the suction valve seat or a noise generated when the
discharge valve hits the discharge valve seat is noticeable, which
causes a noise.
[0013] An object of the present invention is to provide a contact
member, a compressor including the contact member, and a
manufacturing method of the compressor, which can solve the above
described first to third problems.
[0014] In a reciprocating compressor, since the compression
component is supported in a cantilever manner. Therefore, when a
compression load is applied to an eccentric shaft via a connecting
means, a main shaft whirls in an inclined state inside a main
bearing and slides in contact with local regions of the upper end
portion and lower end portion of the main bearing, i.e., in a
partial contact state. When the main shaft continues to slide in
the partial contact state, the solid lubricant abrades away and
thereby the crankshaft abrades away in a refrigerant pump disclosed
in the above Patent Literature 1. As a result, it is difficult to
maintain the performance of the compressor for a long period of
time, or ensure the reliability of the compressor. This is a fourth
problem.
[0015] Another object of the present invention is to provide a
slide member, a compressor including the slide member, and a
manufacturing method of the compressor, which can solve the above
fourth problem.
Solution to Problem
[0016] A contact member and a compressor comprising the contact
member, of the present invention, 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.
[0017] In this configuration, even when contact in a local region
of the contact surface occurs, the synthetic resin of the coating
layer located at the outermost side abrades away. In this way, the
convex portions of roughness vanish at an earlier time, and the
solid lubricant is exposed on the outer surface of the surface
treatment film. As a result, the impact force can be mitigated
effectively.
[0018] In addition, since the coating layer located at the
innermost side has high adhesiveness to the base member of the
contact member, it becomes possible to suppress separation of the
interface of the surface treatment film from the base member, or
separation of the inner portion of the surface treatment film.
Thus, the performance of the contact member can be maintained for a
long period of time, and the reliability of the contact member and
hence the compressor can be ensured.
[0019] A contact member and a compressor comprising the contact
member, of the present invention, 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
an innermost side is larger in elastic deformation amount than the
coating layer located at an outermost side.
[0020] In this configuration, even when contact in a local region
of the contact surface occurs, the coating layer located at the
innermost side (closer to the base member) is elastically deformed,
and thus, the impact force can be mitigated effectively.
[0021] In addition, since the coating layer located at the
outermost side has high strength and high abrasion resistance, it
becomes possible to suppress chipping (separation) or abrasion, and
galling of the surface treatment film. As a result, the performance
of the contact member and hence the compressor can be maintained
for a long period of time, and improved.
[0022] A slide member and a compressor comprising the slide member,
of the present invention, 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.
[0023] 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). For example, the solid
lubricant with a smaller friction coefficient and with a smaller
average particle diameter is placed in the coating layer of the
surface treatment film which is closer to the outer surface of the
main shaft (closer to the base member, inner side), while the solid
lubricant with a higher abrasion resistance and with a larger
average particle diameter is placed in the coating layer of the
surface treatment film which is closer to a main bearing (outer
side).
[0024] In this configuration, even when contact in a local region
of the slide surface occurs, the synthetic resin abrades away after
the sliding is started. In this way, the convex portions of
roughness vanish at an earlier time, and initial abrasion can shift
to steady abrasion at an earlier time. Since the solid lubricant is
exposed on the outer surface of the surface treatment film, the
slide surface which is smooth and has a suitable oil sump can be
formed.
[0025] Even when the coating layer located at the outermost side
abrades away, the coating layer located at the innermost side and
including the solid lubricant with a smaller average particle
diameter and a smaller friction coefficient allows the performance
of the slide member to be maintained for a long period of time. As
a result, the reliability of the slide member and hence the
compressor can be ensured.
[0026] A slide member and a compressor comprising the slide member,
of the present invention, 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.
[0027] In this configuration, even when contact in a local region
of the slide surface occurs, the coating layer located at the
innermost side (closer to the base member) is elastically deformed,
and thus, a contact surface pressure can be mitigated
significantly. In addition, since the coating layer located at the
outermost side has high strength with respect to sliding, the
abrasion and separation of the surface treatment film can be
suppressed.
[0028] A manufacturing method of a compressor of the present
invention comprises (A) applying a first coating agent including
synthetic resin and a solid lubricant to at least a portion of a
slide surface or a contact surface thereof to form a first coating
layer; and (B) applying onto the first coating layer a second
coating agent including a solid lubricant with a larger average
particle diameter than the solid lubricant of the first coating
agent to form a second coating layer.
[0029] In this method, the performance of the compressor can be
maintained for a long period of time.
Advantageous Effects of Invention
[0030] In accordance with the contact member, the slide member, and
the compressor comprising the contact member or the slide member,
of the present invention, the performance of the contact member or
the slide member can be maintained for a long period of time.
[0031] In accordance with the manufacturing method of the
compressor of the present invention, it becomes possible to realize
the compressor which is capable of maintaining its performance for
a long period of time.
BRIEF DESCRIPTION OF DRAWINGS
[0032] FIG. 1 is a vertical sectional view of a compressor
according to Embodiment 1.
[0033] 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.
[0034] FIG. 3 is a cross-sectional view of the major components of
the compressor of FIG. 1.
[0035] FIG. 4 is an enlarged cross-sectional view of A-part of FIG.
3.
[0036] FIG. 5 is a cross-sectional view of a surface treatment film
and a suction valve seat of the compressor according to Embodiment
1.
[0037] FIG. 6 is a cross-sectional view of a suction valve seat
(contact member) of a compressor according to Embodiment 2.
[0038] 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.
[0039] FIG. 8 is a cross-sectional view of the major components of
a compressor according to Embodiment 3.
[0040] FIG. 9 is an enlarged cross-sectional view of B-part of FIG.
8.
[0041] FIG. 10 is a cross-sectional view of the major components of
a compressor according to Embodiment 4.
[0042] FIG. 11 is a cross-sectional view of a discharge valve seat
(contact member) of the compressor according to Embodiment 4.
[0043] FIG. 12 is a cross-sectional view of the major components of
a compressor according to Embodiment 5.
[0044] FIG. 13 is a plan view of a suction valve of FIG. 12.
[0045] FIG. 14 is a cross-sectional view of a suction valve
(contact member) of a compressor according to Embodiment 6.
[0046] FIG. 15 is a cross-sectional view of the major components of
a compressor according to Embodiment 7.
[0047] FIG. 16 is a plan view of a discharge valve of FIG. 15.
[0048] FIG. 17 is a cross-sectional view of a discharge valve
(contact member) of a compressor according to Embodiment 8.
[0049] FIG. 18 is a cross-sectional view of the major components of
a compressor according to Embodiment 9.
[0050] FIG. 19 is a cross-sectional view of the major components of
a compressor according to Embodiment 10.
[0051] FIG. 20 is a vertical sectional view of a compressor
according to Embodiment 11.
[0052] FIG. 21 is an enlarged cross-sectional view of C-part of
FIG. 20.
[0053] 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.
[0054] FIG. 23 is a cross-sectional view of a main shaft (slide
member) of the compressor according to Modified example 1 of
Embodiment 11.
[0055] FIG. 24 is a vertical sectional view of a compressor
according to Embodiment 12.
[0056] FIG. 25 is an enlarged cross-sectional view of D-part of
FIG. 24.
[0057] FIG. 26 is a schematic view showing the configuration of a
pneumatic syringe dispenser device.
[0058] FIG. 27 is a schematic view showing the outline of
manufacturing a surface treatment film, by using the device of FIG.
26.
[0059] FIG. 28 is a vertical sectional view of a compressor
according to Modified example 1 of Embodiment 12.
[0060] FIG. 29 is an enlarged cross-sectional view of E-part of
FIG. 28.
DESCRIPTION OF EMBODIMENTS
[0061] 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
[0062] 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.
[0063] In the compressor according to Embodiment 1, the surface
treatment film may include a solid lubricant.
[0064] In the compressor according to Embodiment 1, the surface
treatment film may have a thickness of 1 .mu.m to 20 .mu.m.
[0065] 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.
[0066] 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.
[0067] 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.
[0068] [Configuration of Compressor]
[0069] 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.
[0070] 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.
[0071] 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.
[0072] 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.
[0073] 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.
[0074] 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.
[0075] 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.
[0076] 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.
[0077] 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.
[0078] 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.
[0079] 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.
[0080] 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.
[0081] 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 120a is provided on the suction
valve 120 in a location corresponding to the discharge hole 119.
The U-shaped opening/closing section 120a 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.
[0082] [Configuration of Surface Treatment Film]
[0083] 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.
[0084] 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.
[0085] 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 .mu.m 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 .mu.m.
[0086] 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 (MoS.sub.2). 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.
[0087] 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.
[0088] Although in Embodiment 1, molybdenum disulfide (MoS.sub.2)
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
(Sb.sub.2O.sub.3).
[0089] 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.
[0090] [Manufacturing Method of Surface Treatment Film]
[0091] Next, the manufacturing method of the surface treatment film
160 will be described.
[0092] 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.
[0093] 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.
[0094] 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.
[0095] 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.
[0096] [Operation of Compressor]
[0097] Next, the operation of the sealed compressor 100 according
to Embodiment 1 will be described with reference to FIGS. 1 to
4.
[0098] 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.
[0099] 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.
[0100] Next, the suction stroke and the compression stroke of the
compressor 100 will be described more specifically.
[0101] 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.
[0102] 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.
[0103] 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.
[0104] 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.
[0105] [Advantage of Compressor]
[0106] Next, the advantage of the compressor 100 according to
Embodiment 1 will be described with reference to FIGS. 1 to 5.
[0107] 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.
[0108] 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.
[0109] 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.
[0110] 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.
[0111] 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.
[0112] 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.
[0113] Therefore, the compressor 100 according to Embodiment 1 is
capable of suppressing reduction of a refrigeration capability and
increasing the efficiency at low cost.
[0114] 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.
[0115] 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.
[0116] 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.
[0117] 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.
[0118] 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.
[0119] In the compressor 100 according to Embodiment 1, by setting
the thickness of the surface treatment film 160 to 1 .mu.m 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 .mu.m 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.
[0120] 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
[0121] 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.
[0122] 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.
[0123] 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).
[0124] 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.
[0125] 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.
[0126] In the contact member according to Embodiment 2, the
thickness of the surface treatment film may be set to 1 to 30
.mu.m.
[0127] 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.
[0128] 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.
[0129] 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.
[0130] 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.
[0131] [Configuration of Compressor (Contact Member)]
[0132] FIG. 6 is a cross-sectional view of the suction valve seat
(contact member) of the compressor according to Embodiment 2.
[0133] 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 160a and a second coating layer 160b.
[0134] Specifically, the first coating layer 160a is located at the
outer surface side of the suction valve seat 141 (innermost side),
while the second coating layer 160b is located outward relative to
the first coating layer 160a (outermost side). In Embodiment 2, the
first coating layer 160a and the second coating layer 160b 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.
[0135] The first coating layer 160a 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 .mu.m or
smaller and is dispersed substantially uniformly in the synthetic
resin 161 such that the solid lubricant 162 in the first coating
layer 160a has a content percentage which is smaller than 33%. As
in the first coating layer 160a, the second coating layer 160b
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 .mu.m or larger and 5 .mu.m or smaller and
is dispersed substantially uniformly in the synthetic resin 161
such that the solid lubricant 162 in the second coating layer 160b
has a content percentage which is equal to or larger than 33%.
[0136] Since the solid lubricant 162 is higher in mechanical
strength than the synthetic resin 161, the elastic deformation
amount of the first coating layer 160a can be made larger than that
of the second coating layer 160b by setting the content percentage
of the solid lubricant 162 in the first coating layer 160a lower
than that of the solid lubricant 162 in the second coating layer
160b.
[0137] Or, the content percentage of the solid lubricant 162 in the
first coating layer 160a may be made lower than that of the solid
lubricant 162 in the second coating layer 160b by setting the
quantity (weight) of the solid lubricant 162 in the first coating
layer 160a smaller than that of the solid lubricant 162 in the
second coating layer 160b, under the condition in which the average
particle diameter of the synthetic resin 161 is set equal.
[0138] Or, the elastic deformation amount of the first coating
layer 160a may be made larger than that of the second coating layer
160b 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 160a may comprise the phenol resin
having a relatively soft property to increase the elastic
deformation amount, while the second coating layer 160b may
comprise polyamide resin having a relatively hard property to
reduce the elastic deformation amount.
[0139] 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 160a may be equal to or larger than 1%
and smaller than 33%.
[0140] As shown in FIG. 6, the surface treatment film 160 is
configured such that the thickness of the first coating layer 160a
is smaller than the thickness of the second coating layer 160b and
set to about 10 .mu.m in Embodiment 2.
[0141] Although in Embodiment 2, the thickness of the first coating
layer 160a is set smaller than the thickness of the second coating
layer 160b, the present invention is not limited to this. The
thickness of the first coating layer 160a may be equal to or larger
than that of the second coating layer 160b.
[0142] Although in Embodiment 2, the thickness of the surface
treatment film 160 is set to about 10 .mu.m, 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 .mu.m, 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 .mu.m. 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 .mu.m
and equal to or smaller than 20 .mu.m.
[0143] [Manufacturing Method of Surface Treatment Film]
[0144] Next, the manufacturing method of the surface treatment film
160 will be described.
[0145] 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.
[0146] Then, prepared is a first surface treatment agent for the
first coating layer 160a with a specified viscosity and a second
surface treatment agent for the second coating layer 160b 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.
[0147] 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 160a. Then, the second surface treatment agent
is applied to the surface of the first coating layer 160a by
spraying.
[0148] 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 160b 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 160b), 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 160b). 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.
[0149] 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.
[0150] [Advantage of Compressor]
[0151] Next, the advantage of the compressor 100 according to
Embodiment 2 will be described with reference to FIG. 6.
[0152] In the compressor 100 according to Embodiment 2, the first
coating layer 160a 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 160b including the solid lubricant 162 with a larger average
particle diameter is placed in a location that is closer to the
suction valve 120.
[0153] In this configuration, the synthetic resin 161 of the second
coating layer 160b abrades away, and thereby the solid lubricant
162 is exposed on the outer surface of the surface treatment film
160 (second coating layer 160b) 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 160a
is elastically deformed to mitigate the impact force effectively, a
contact surface pressure can be mitigated significantly.
[0154] 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.
[0155] Since the solid lubricant 162 is exposed on the outer
surface of the surface treatment film 160 (second coating layer
160b) 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.
[0156] Since the solid lubricant 162 with a lipophilic property is
exposed on the outer surface of the surface treatment film 160
(second coating layer 160b) 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.
[0157] Since the solid lubricant 162 included in the first coating
layer 160a 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 160a) and the suction valve seat 141, and separation between
the first coating layer 160a and the second coating layer 160b.
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.
[0158] In the compressor 100 according to Embodiment 2, the first
coating layer 160a 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
[0159] Next, the modified example of the compressor (contact
member) according to Embodiment 2 will be described.
[0160] 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.
[0161] 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.
[0162] 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.
[0163] 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 160a, the second coating layer 160b, and a third
coating layer 160c.
[0164] Specifically, the third coating layer 160c is placed between
the first coating layer 160a and the second coating layer 160b. The
first coating layer 160a and the third coating layer 160c which are
adjacent to each other are configured such that the content
percentage of the solid lubricant 162 in the first coating layer
160a is lower than the content percentage of the solid lubricant
162 in the third coating layer 160c. Also, the third coating layer
160c and the second coating layer 160b which are adjacent to each
other are configured such that the content percentage of the solid
lubricant 162 in the third coating layer 160c is lower than the
content percentage of the solid lubricant 162 in the second coating
layer 160b.
[0165] In this configuration, the elastic deformation amount of the
first coating layer 160a can be made larger than the elastic
deformation amount of the third coating layer 160c. In addition,
the elastic deformation amount of the third coating layer 160c can
be made larger than the elastic deformation amount of the second
coating layer 160b.
[0166] 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
[0167] 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.
[0168] 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.
[0169] 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.
[0170] 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.
[0171] 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.
[0172] 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.
[0173] 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.
[0174] Therefore, the compressor 100 according to Embodiment 3 can
suppress reduction of a refrigeration capability, reduce cost, and
increase the efficiency.
[0175] 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.
[0176] 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.
[0177] 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.
[0178] 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.
[0179] 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.
[0180] 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
[0181] 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.
[0182] 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.
[0183] 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.
[0184] 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.
[0185] 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.
[0186] 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.
[0187] 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 160a and a second coating layer 160b. The
configuration of the surface treatment film 160 (first coating
layer 160a and second coating layer 160b) of Embodiment 4 is the
same as that of the surface treatment film 160 (first coating layer
160a and second coating layer 160b) of Embodiment 2, and therefore
will not be described in detail repeatedly.
[0188] In the compressor 100 according to Embodiment 4 configured
as described above, the first coating layer 160a 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 160b including the
solid lubricant 162 with a larger average particle diameter is
placed in a location that is closer to the discharge valve 121.
[0189] In this configuration, the synthetic resin 161 of the second
coating layer 160b abrades away, and thereby the solid lubricant
162 is exposed on the outer surface of the surface treatment film
160 (second coating layer 160b) at an earlier time. This can
mitigate the impact force effectively. In addition, since the first
coating layer 160a is elastically deformed to mitigate the impact
force effectively, a contact surface pressure can be mitigated
significantly.
[0190] 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.
[0191] Since the solid lubricant 162 is exposed on the outer
surface of the surface treatment film 160 (second coating layer
160b) 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.
[0192] Since the solid lubricant 162 with a lipophilic property is
exposed on the outer surface of the surface treatment film 160
(second coating layer 160b) 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.
[0193] Since the solid lubricant 162 included in the first coating
layer 160a 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 160a) and the discharge valve seat 142, and separation
between the first coating layer 160a and the second coating layer
160b. 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.
[0194] In the compressor 100 according to Embodiment 4, the first
coating layer 160a 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.
[0195] 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
[0196] 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.
[0197] 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.
[0198] 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.
[0199] 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.
[0200] 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.
[0201] 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.
[0202] 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.
[0203] 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.
[0204] 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
[0205] 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.
[0206] 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.
[0207] 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.
[0208] 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.
[0209] 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.
[0210] FIG. 14 is a cross-sectional view of a suction valve
(contact member) of a compressor according to Embodiment 6.
[0211] 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
160a and a second coating layer 160b. The configuration of the
surface treatment film 160 (first coating layer 160a and second
coating layer 160b) of Embodiment 6 is the same as that of the
surface treatment film 160 (first coating layer 160a and second
coating layer 160b) of Embodiment 2, and therefore will not be
described in detail repeatedly.
[0212] 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
[0213] 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.
[0214] 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.
[0215] 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.
[0216] 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.
[0217] In FIG. 16, the portion of the surface treatment film and
the discharge valve, which portion contacts the discharge valve
seat is hatched.
[0218] 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.
[0219] 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.
[0220] 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.
[0221] 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.
[0222] 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
[0223] 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.
[0224] 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.
[0225] 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.
[0226] 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.
[0227] 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.
[0228] FIG. 17 is a cross-sectional view of the discharge valve
(contact member) of the compressor according to Embodiment 8.
[0229] 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 160a
and a second coating layer 160b. The configuration of the surface
treatment film 160 (first coating layer 160a and second coating
layer 160b) of Embodiment 8 is the same as that of the surface
treatment film 160 (first coating layer 160a and second coating
layer 160b) of Embodiment 2, and therefore will not be described in
detail repeatedly.
[0230] 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
[0231] 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.
[0232] 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.
[0233] 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.
[0234] 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.
[0235] 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.
[0236] 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.
[0237] FIG. 18 is a cross-sectional view of the major components of
the compressor according to Embodiment 9.
[0238] 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.
[0239] 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.
[0240] 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.
[0241] 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
[0242] 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.
[0243] 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.
[0244] 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.
[0245] 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.
[0246] 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.
[0247] 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.
[0248] FIG. 19 is a cross-sectional view of the major components of
the compressor according to Embodiment 10.
[0249] 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.
[0250] 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.
[0251] 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.
[0252] 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
[0253] 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.
[0254] 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.
[0255] 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.
[0256] 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.
[0257] 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.
[0258] In the slide member according to Embodiment 11, the surface
treatment film may have a thickness of 1 to 10 .mu.m.
[0259] 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.
[0260] 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.
[0261] 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.
[0262] 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.
[0263] [Configuration of Compressor]
[0264] 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.
[0265] 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.
[0266] 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.
[0267] The thickness of the surface treatment film 160 may be equal
to or larger than 1 .mu.m to improve a sliding capability, or may
be equal to or smaller than 10 .mu.m 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 .mu.m and may
be equal to or smaller than 6 .mu.m to improve a sliding capability
and efficiently manufacture the surface treatment film 160.
[0268] 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.
[0269] 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.
[0270] 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.
[0271] 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.
[0272] 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.
[0273] 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.
[0274] 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).
[0275] 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.
[0276] 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.
[0277] 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.
[0278] 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.
[0279] 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.
[0280] 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 160b 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.
[0281] Thereafter, the second coating layer 160b abrades away, and
the first coating layer 160a is exposed as the outer surface. Since
the first coating layer 160a 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.
[0282] In the compressor 100 according to Embodiment 11, even when
local-contact sliding occurs, the first coating layer 160a 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 160b
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.
[0283] In the compressor 100 according to Embodiment 1, the first
coating layer 160a 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 160a 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.
[0284] 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.
[0285] 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.
[0286] 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
[0287] Next, modified example of the compressor (slide member)
according to Embodiment 11 will be described.
[0288] 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.
[0289] 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.
[0290] FIG. 23 is a cross-sectional view of a main shaft (slide
member) of the compressor according to Modified example 1 of
Embodiment 11.
[0291] 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 160a,
the second coating layer 160b, and the third coating layer
160c.
[0292] Specifically, the third coating layer 160c is placed between
the first coating layer 160a and the second coating layer 160b. The
first coating layer 160a and third coating layer 160c which are
adjacent to each other are configured such that the content
percentage of the solid lubricant 162 in the first coating layer
160a is lower than the content percentage of the solid lubricant
162 in the third coating layer 160c. Also, the third coating layer
160c and the second coating layer 160b which are adjacent to each
other are configured such that the content percentage of the solid
lubricant 162 in the third coating layer 160c is lower than the
content percentage of the solid lubricant 162 in the second coating
layer 160b.
[0293] In this configuration, the elastic deformation amount of the
first coating layer 160a can be made larger than the elastic
deformation amount of the third coating layer 160c. In addition,
the elastic deformation amount of the third coating layer 160c can
be made larger than the elastic deformation amount of the second
coating layer 160b.
[0294] 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.
[0295] 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
[0296] 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.
[0297] In the compressor according to Embodiment 12, a plurality of
surface treatment films may be placed in parallel.
[0298] 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.
[0299] In the compressor according to Embodiment 12, the surface
treatment film may have a thickness of 1 to 10 .mu.m.
[0300] 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.
[0301] [Configuration of Compressor]
[0302] 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.
[0303] 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.
[0304] 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 111a of the
main shaft 111. A recessed groove 165 is provided between adjacent
surface treatment films 160.
[0305] The length of the surface treatment film 160 in the
direction of the center axis 111a 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 111a may be set suitably depending
on the operation conditions of the compressor 100, etc., and may
be, for example, about 0.5 mm.
[0306] The thickness of the surface treatment film 160 may be equal
to or larger than 1 .mu.m to increase the productivity of the
surface treatment film 160, and may be equal to or smaller than 10
.mu.m 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 .mu.m and equal
to or smaller than 6 .mu.m to improve the sliding characteristic of
the surface treatment film 160 and efficiently manufacture the
surface treatment film 160.
[0307] 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.
[0308] 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).
[0309] [Manufacturing Method of Surface Treatment Film]
[0310] Next, the manufacturing method of the surface treatment film
160 will be described with reference to FIGS. 24 to 27.
[0311] 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.
[0312] Initially, the configuration of the pneumatic syringe
dispenser device will be described with reference to FIG. 26.
[0313] 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).
[0314] Next, the manufacturing method of the surface treatment film
160 will be described with reference to FIGS. 24 to 27.
[0315] 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.
[0316] 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 111a, 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.
[0317] 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.
[0318] 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.
[0319] 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.
[0320] 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.
[0321] 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.
[0322] 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
[0323] Next, the modified example of the compressor (contact
member) according to Embodiment 12 will be described.
[0324] 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.
[0325] 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.
[0326] 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.
[0327] 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.
[0328] 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.
[0329] Specifically, the surface treatment film 160 is configured
such that the inclination angle with respect to the center axis
111a 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 111a of the main shaft 111. In other words, the
inclination angle of the recessed groove 165 with respect to the
center axis 111a is smaller than the inclination angle of the
groove 183 of with respect to the center axis 111a.
[0330] 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.
[0331] 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.
[0332] 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.
[0333] 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 111a is smaller than the
inclination angle of the groove 183 with respect to the center axis
111a. 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.
[0334] 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.
[0335] 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
[0336] A contact member, a slide member, a compressor including
comprising the contact member or the slide member, and a
manufacturing method of the compressor, can maintain the
performance for a long period of time, or improve the performance.
Therefore, these are widely applicable to examples using
refrigeration cycles, such as home refrigerators, air conditioners,
dehumidification machines, show cases, vending machines, etc.
[0337] A manufacturing method of the compressor can realize the
compressor which can maintain the performance for a long period of
time, or improve the performance, and the compressor is widely
applicable to examples using refrigeration cycles, such as home
refrigerators, air conditioners, dehumidification machines, show
cases, vending machines, etc.
REFERENCE SIGNS LIST
[0338] 100 compressor [0339] 101 sealed container [0340] 102
lubricating oil [0341] 103 refrigerant [0342] 104 compressor body
[0343] 105 suspension spring [0344] 106 electric component [0345]
107 stator [0346] 108 rotor [0347] 109 compression component [0348]
110 eccentric shaft [0349] 111 main shaft [0350] 111a center axis
[0351] 112 crankshaft [0352] 113 compression chamber [0353] 114
cylinder [0354] 115 block [0355] 116 piston [0356] 117 valve plate
[0357] 118 suction plate [0358] 119 discharge hole [0359] 120
suction valve [0360] 120a opening/closing section [0361] 121
discharge valve [0362] 122 connecting means [0363] 123 bearing
section [0364] 130 spring reed [0365] 131 valve stop [0366] 132
recessed portion [0367] 141 suction valve seat [0368] 142 discharge
valve seat [0369] 150 suction pipe [0370] 151 oil feeding mechanism
[0371] 152 cylinder head [0372] 153 head bolt [0373] 154 suction
muffler [0374] 156 head space [0375] 157 discharge pipe [0376] 160
surface treatment film [0377] 160a first coating layer [0378] 160b
second coating layer [0379] 160c third coating layer [0380] 161
synthetic resin [0381] 162 solid lubricant [0382] 163 contact
portion [0383] 164 contact portion [0384] 165 recessed groove
[0385] 180 first slide section [0386] 181 connecting section [0387]
182 second slide section [0388] 183 groove [0389] 300 pneumatic
syringe dispenser device [0390] 301 air source [0391] 302 regulator
[0392] 303 discharge timer [0393] 304 controller [0394] 305
electric power supply [0395] 306 syringe [0396] 307 nozzle [0397]
313 coating agent
* * * * *