Patent Application
20220163044
The present invention relates to a sliding bearing used in an electric water pump that comprises a rotor having the sliding bearing that rotatably supports a shaft, and a stator that rotationally drives the rotor. In particular, a sliding bearing for an electric water pump that cools an inverter or a combustion engine of a vehicle.
Conventionally, an electric water pump used for cooling an inverter or a combustion engine of a vehicle has been proposed in Patent Document 1. A structure of a rotor of this kind of the electric water pump will be described with reference to
A structure and an action of the electric water pump using the rotor shown in
Patent Document 2 discloses a sliding bearing for an electric water pump using a molded body of a phenol resin composition. The phenol resin composition contains phenol resin as a main component and contains at least (A) carbon fiber and (B) at least one solid lubricant selected from among polytetrafluoroethylene (PTFE) resin and graphite.
Patent Document 3 discloses a composite material in a resin composite sliding member to be used in water, the composite material includes PTFE resin containing at least one filling material selected from among carbon fiber, graphite, boron nitride, molybdenum disulfide, and tungsten disulfide.
An antifreeze solution such as long-life coolant containing ethylene glycol is generally adopted as cooling water for the electric water pump. In Patent Documents 1 to 3, the performance of the sliding bearing in the antifreeze solution has not been evaluated, and therefore there is room for improvement in low friction performance of the sliding bearing in water or an antifreeze solution.
An object of the present invention is, in order to solve such problems, to provide a sliding bearing for an electric water pump, the sliding bearing being superior in low friction performance in water or an antifreeze solution.
A sliding bearing for an electric water pump of the present invention (hereinafter, also referred to as merely a sliding bearing) is for the electric water pump that comprises a rotor having the sliding bearing that is formed in a substantially hollow cylindrical shape and rotatably supports a shaft, and a stator that is disposed on a circle coaxial with the shaft and rotationally drives the rotor. The sliding bearing is formed of a resin composition that contains synthetic resin as a main component. The resin composition contains carbon fiber having a density of 2.00-2.25 g/cm3 and an average fiber length of 30-300 μm.
The resin composition may contain 5-30 vol % of the carbon fiber to a whole volume of the resin composition.
The resin composition may contain 1-20 vol % of PTFE resin and 1-30 vol % of graphite.
The synthetic resin may be PPS resin or polyether ether ketone (PEEK) resin.
The sliding bearing may be configured to be used such that at least one end surface among both end surfaces in an axial direction of the sliding bearing is slid on a mating material formed of stainless steel while receiving an axial load.
In the sliding bearing for the electric water pump of the present invention, the resin composition that forms the sliding bearing contains carbon fiber having a density of 2.00-2.25 g/cm3 and an average fiber length of 30-300 μm. Thus, the breakage of the carbon fiber when being slid on the mating material in water or an antifreeze solution and accumulation of the broken carbon fiber on the sliding surface become less, and therefore superior low friction performance is obtained.
The resin composition contains 5-30 vol % of carbon fiber having an average fiber length of 30-300 μm. Thus, the number of the fibers of the carbon fiber per unit volume of the resin composition is set appropriately, and accordingly points (load points) on the sliding surface where receive a load are increased. With this, water film is easily formed on the sliding surface in water or an antifreeze solution, and thereby low friction performance is obtained.
The resin composition contains 1-20 vol % of PTFE resin and 1-30 vol % of graphite. Consequently, a lower friction state is achieved. In addition, the mating material formed of stainless steel is hardly damaged.
The present inventor conducted a study relating to a resin composition in a resin sliding bearing used in water or an antifreeze solution. As a result of the study, the present inventor found that low friction performance of the sliding bearing in water or an antifreeze solution can be improved by using carbon fiber having a density of 2.00-2.25 g/cm3. The present invention has been derived from such knowledge.
A sliding bearing of the present invention is used in an electric water pump that comprises a rotor having the sliding bearing that rotatably supports a shaft, and a stator that is disposed on a circle coaxial with the shaft and rotationally drives the rotor. The sliding bearing is formed of a resin composition containing synthetic resin such as PPS resin as a main component. The resin composition contains carbon fiber having a density of 2.00-2.25 g/cm3, and an average fiber length of 30-300 μm. It is preferable that the sliding bearing is an injection molded body.
In the embodiment shown in
The sliding bearing 3 is a substantially hollow cylindrical body having a bearing hole 3a for rotatably supporting the shaft, at a center part in a radial direction. A cylindrical inner diametrical surface that forms the bearing hole 3a serves as a radial bearing surface (sliding surface). An outer diametrical shape of the sliding bearing 3 (for example, a ratio of a length of the cylindrical body or a ratio of a thickness of the cylindrical body to an outer diameter of the cylindrical body) is not especially limited, and therefore the outer diametrical shape may be set as needed in response to a configuration of the electric water pump. When the electric water pump is driven, at least one of both end surfaces in an axial direction of the sliding bearing 3 is slid on a mating material while receiving an axial load.
The sliding bearing 3 shown in
In the present invention, the sliding bearing is formed of a resin composition containing synthetic resin as a main component. The resin composition contains carbon fiber having a density of 2.00-2.25 g/cm3 and an average fiber length of 30-300 μm. Here, the synthetic resin as a main component is compounded by 50 vol % or more, preferably 60 vol % or more, to the whole volume of the resin composition.
It is considered that breakage of the carbon fiber or accumulation of the broken carbon fiber on the sliding surface when slid on the mating material in water or an antifreeze solution is less by using the carbon fiber having the density of 2.00-2.25 g/cm3 adopted in the present invention compared to carbon fiber having a density of 1.60-1.99 g/cm3 and therefore low friction performance is obtained. In order to manufacture the carbon fiber having the density of 2.00-2.25 g/cm3, it is preferable to adopt a mesophase pitch that is easily graphitized, as a raw material. In a case in which an isotropic pitch or acrylonitrile (PAN) is adopted as a raw material, graphitization to obtain the density of 2.00-2.25 g/cm3 is difficult. The density of the carbon fiber is determined by a liquid displacement method, a sink/float method, or a density-gradient column method (JIS R 7603:1999). The density of the carbon fiber is preferably set to 2.10-2.25 g/cm3.
The carbon fiber adopted in the present invention has an average fiber length of 30-300 μm. Example of the carbon fiber includes milled fiber produced by grinding chopped fiber. The average fiber length in the present invention denotes the number average fiber length. In a case in which the average fiber length is less than 30 μm, the obtained reinforcing effect becomes inferior and thereby wear resistance is deteriorated. In a case in which the average fiber length is more than 300 μm, the number of fibers per unit volume of the resin composition becomes less and thereby load points on the sliding surface are decreased. When the load points are decreased, water film is hardly formed on the sliding surface and thereby the friction coefficient is liable to be high. The average fiber length is preferably set to 50-200 μm.
Examples of the milled fiber that is commercially available adopted in the present include DIALEAD K223HM-200 μm (average fiber length of 200 μm, average fiber diameter of 11 μm, density of 2.22 g/cm3) and DIALEAD K223HM-50 μm (average fiber length of 50 μm, average fiber diameter of 11 μm, density of 2.22 g/cm3) produced by Mitsubishi Chemical Corporation, and HC-600-15M (average fiber length of 150 μm, average fiber diameter of 10 μm, density of 2.22 g/cm3) produced by Nippon Graphite Fiber Corporation.
The average fiber diameter of the carbon fiber adopted in the present invention is not especially limited, however it is set to, for example, 5-20 μm, preferably 10-20 μm. The average fiber diameter is measured by an electron microscope or an atomic force microscope generally used in this field. Further, the average fiber diameter is calculated as a number average fiber diameter based on the above measurement.
A compound amount of the carbon fiber having the density of 2.00-2.25 g/cm3 is set to preferably 5-30 vol %, more preferably set to 10-30 vol %, and furthermore preferably 10-20 vol % to the whole volume of the resin composition. In a case in which the compound amount of the carbon fiber is less than 5 vol %, the obtained reinforcing effect becomes inferior and thereby wear resistance might be deteriorated. Further, in a case in which the compound amount of the carbon fiber is more than 30 vol %, the cost is liable to be high.
A kind of the synthetic resin adopted in the above resin composition is not especially limited, however it is preferable to adopt super engineering plastic as the synthetic resin from a viewpoint of heat resistance. Specifically, examples of the synthetic resin include PPS resin, PEEK resin, polyamide-imide (PAI) resin, PTFE resin, polyvinylidene fluoride resin, liquid crystal polymer, polyether sulfone resin, polysulfone resin, polyarylate resin, polyether-imide resin, and polyimide resin. Considering the use in water or an antifreeze solution, PPS resin or PEEK resin having low water absorption performance and superior chemical resistance is preferable, and the PPS resin that is relatively low in cost among super engineering plastics is more preferable.
PPS resin is crystalline thermoplastic resin having a polymer structure in which benzene rings are linked by sulfides at the para-position. PPS resin has the melting point of approximately 280° C. and the glass transition temperature (Tg) of 93° C. and has extremely high rigidity, and superior heat resistance, dimensional stability, and wear resistance. There are several types of PPS resin including crosslinked type, semi-crosslinked type, straight chain type, and branched chain type defined by its molecular structure. In the present invention, any type of PPS resin may be adopted regardless of the molecular structure and molecular weight thereof.
It is preferable that the resin composition contains PTFE resin and graphite (graphite) in addition to the synthetic resin and the carbon fiber. The compound rate of the PTFE resin is set to preferably 1-20 vol %, more preferably 3-20 vol %, and further more preferably 10-20 vol % to the whole volume of the resin composition. Further, the compound rate of the graphite is set to preferably 1-30 vol %, more preferably 3-30 vol %, and further more preferably 10-30 vol % to the whole volume of the resin composition.
PTFE resin is a solid lubricant that may decrease a dynamic friction coefficient of a molded body in a boundary lubrication state such as a water-poor state that cannot cause water film. As the PTFE resin, any of molding powder obtained through a suspension polymerization method, fine powder obtained through an emulsion polymerization method, and recycled PTFE may be adopted. In order to stable the flowability of the resin composition, it is preferable to adopt the recycled PTFE that is hardly fibered by the shearing in molding and hardly increases the melting viscosity. The recycled PTFE denotes heat-treated powder (heat hysteresis has been applied), or powder that has been irradiated with γ rays or electron rays. Examples of the recycled PTFE include powder formed by heat-treating the molding powder or the fine powder, powder formed by irradiating the powder formed by heat-treating the molding powder or the fine powder, with γ rays or electron rays, powder formed by grinding a molding body of the molding powder or the fine powder, powder formed by irradiating the powder formed by grinding a molding body of molding powder or fine powder, with γ rays or electron rays, and powder formed by irradiating the molding powder or the fine powder with γ rays or electron rays.
Examples of the PTFE resin that is commercially available adopted in the present invention, include KTL-610, KTL-450, KTL-350, KTL-8N, and KTL-400H produced by KITAMURA LIMITED; Teflon (registered trademark) 7-J and TLP-10 produced by Chemours-Mitsui Fluoroproducts Co., Ltd.; Fluon G163, L150J, L169J, L170J, L172J, and L173J produced by AGC Inc.; Polyflon M-15 and Lubron L-5 produced by DAIKIN INDUSTRIES, LTD.; and Dyneon TF9205 and TF9207 produced by 3M Japan Limited. Further, PTFE resin modified by a perfluoroalkylether group, a fluoroalkyl group, or a side chain group containing other fluoroalkyl may be adopted. The PTFE resin irradiated with γ rays or electron rays among the PTFE resins described above corresponds to KTL-610, KTL-450, KTL-350, KTL-8N, and KTL-8F produced by KITAMURA LIMITED; and Fluon L169J, L170J, L172J, and L173J produced by AGC Inc.
The graphite is a solid lubricant that may decrease, similar to the PTFE resin, a dynamic friction coefficient in a boundary lubrication state. The graphite has an advantage that improves wear property and elastic modulus of the sliding bearing and also improves dimensional accuracy of the sliding bearing in injection molding. Any of natural graphite and artificial graphite may be adopted as the graphite. A shape of a particle may be a scaly shape, a spherical shape, or the like. The scaly shape is more preferable because the particle is hardly dropped off in sliding. An example of the natural graphite includes ACP produced by Nippon Graphite Industries, Co.,Ltd. Examples of the artificial graphite include KS-6, KS-25, and KS-44 produced by Imerys Graphite & Carbon Japan Ltd.
In the sliding bearing of the present invention, it is preferable that at least one end surface among both end surfaces in the axial direction of the sliding bearing is slid on the mating material formed of stainless steel while receiving an axial load. The stainless steel is defined by JIS G 0203. By adopting the resin composition described above, the mating material formed of stainless steel is hardly damaged, and therefore a favorable sliding state is maintained.
A well-known additive for resin may be compounded into the resin composition described above to some extent that does not deteriorate an advantage of the present invention. Examples of the additive include a friction property improving agent such as boron nitride, molybdenum disulfide, and tungsten disulfide, and a coloring agent such as carbon black, iron oxide, and titanium oxide.
After the materials that forms the resin composition described above are mixed as needed using a Henschel mixer, a ball mixer, a ribbon blender or the like, the materials are melt-kneaded using a melt extruder such as a twin-screw melt extruder to obtain molding pellets. Further, during melt-kneading in a twin-screw melt extruder or the like, a side feed may be adopted for charging the filling material. The sliding bearing is molded by injection molding using these molding pellets.
The rotor for an electric water pump of the present invention is provided with the main body that supports the impeller of the pump, the sliding bearing that rotatably supports the shaft, and the magnet that is arranged to face the stator. In
The second resin composition contains synthetic resin (hereinafter, referred to as a second synthetic resin) as a main component. This synthetic resin is not especially limited, the synthetic resin (hereinafter, referred to as a first synthetic resin) exemplarily described in the first resin composition may be adopted. It is preferable that the second synthetic resin is a thermoplastic resin having the melting point equal to or less than that of the first synthetic resin. For example, in a case in which PPS resin is adopted as the first synthetic resin, it is preferable to adopt PBT resin or PPS resin as the second synthetic resin, and in this case, PPS resin is more preferable. In a case in which PEEK resin is adopted as the first synthetic resin, it is preferable to adopt PPS resin as the second synthetic resin. It is not preferable to adopt a thermoplastic resin having the melting point more than that of the first synthetic resin as the second synthetic resin because deformation is extremely caused on the sliding bearing in the insert molding.
It is preferable to compound a compounding material into the second resin composition that forms the main body. For example, a reinforcing material such as glass fiber, carbon fiber, whisker, mica, and talc may be compounded in order to enhance strength, elasticity, and dimensional accuracy, and an inorganic filling material such as mineral, calcium carbonate, and glass beads may be compounded in order to eliminate anisotropy of shrinkage in injection molding. As the compounding material, a low cost reinforcing material such as glass fiber is preferably compounded.
A resin composition that adopts PPS resin as the second synthetic resin and contains 5-30 vol % of the glass fiber to the whole volume of the resin composition is preferable as the second resin composition. It is preferable that the resin composition does not contain the carbon fiber.
The electric water pump that adopts the sliding bearing of the present invention and the rotor uses water or an antifreeze solution containing ethylene glycol, as cooling water. It is preferable that the compound rate of the ethylene glycol in the antifreeze solution is 30-70 vol % to the whole volume of the antifreeze solution.
The raw materials of the resin compositions used in Examples and Comparative examples are collective described below. The raw materials (1) to (8) were melt-kneaded by a twin-screw melt extruder, so that pellets were produced.
Tosoh Corporation: B-042
Victrex Japan Inc.: PEEK 150P
Mitsubishi Chemical Corporation: DIALEAD K223HM-50 μm (average fiber length: 50 μm, average fiber diameter: 11 μm, density: 2.22 g/cm3)
Mitsubishi Chemical Corporation: DIALEAD K223HM-200 μm (average fiber length: 200 μm, average fiber diameter: 11 μm, density: 2.22 g/cm3)
Kureha Corporation: KRECA M-101S (average fiber length: 150 μm, average fiber diameter: 14.5 μm, density: 1.63 g/cm3)
Toho Tenax Co., Ltd.: BESFIGHT HT M800 160MU (average fiber length: 160 μm, average fiber diameter: 7 μm, density: 1.77 g/cm3)
KITAMURA LIMITED: KTL-610 (recycled PTFE)
Imerys Graphite & Carbon Japan Ltd.: KS-6 (artificial graphite, scaly shape)
The resin compositions of Examples 1 to 6 and Comparative examples 1 to 3 are shown in Tables 1 and 2. Cylindrical specimens having an inner diameter of 10 mm, an outer diameter of 17 mm and a height of 13 mm were produced from the resin compositions by means of injection molding. The dynamic friction coefficient in an antifreeze solution (ethylene glycol 50 vol % and water 50 vol %) of each of the produced cylindrical specimens and the disc-shape mating materials (SUS304) was measured using a ring on disc tester. The test condition is velocity of 125 m/minute, surface pressure of 1 MPa, and temperature of 50° C. The measured values of the dynamic friction coefficients are also shown in Tables 1 and 2.
As shown in Tables 1 and 2, the dynamic friction coefficients of Examples 1 to 6 are in a range of 0.04-0.05, which is lower than a range of 0.07-0.11 of the dynamic friction coefficients of Comparative examples 1 to 3. Consequently, the Examples 1 to 6 are superior in low friction performance in an antifreeze solution.
Further, photos taken by a metallurgical microscope of sliding surfaces of the cylindrical specimens of Example 3 and Comparative examples 1 and 2 are shown in
In Example 3 (
The sliding bearing for an electric water pump of the present invention is superior in low friction performance in water or an antifreeze solution. Consequently, the sliding bearing of the present invention can be preferably used as a sliding bearing for an electric water pump that cools a combustion engine or an inverter of a vehicle.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2019-063454 | Mar 2019 | JP | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/JP2020/009318 | 3/5/2020 | WO | 00 |
