Plastic composite containing magnetic alloy powder, air conditioner compressor having the same and method of producing them

Patent metadata

Field	Value
Publication number	US-2019203780-A1
Application number	US-201816214319-A
Country	US
Kind code	A1
Filing date	Dec 10, 2018
Priority date	Dec 29, 2017
Publication date	Jul 4, 2019
Grant date	—

Abstract

Disclosed is a plastic composite including a magnetic alloy material in an amount of about 20% by volume or greater on the basis of the total volume of the plastic composite. Accordingly, weight of the clutch may be reduced by about 0.4 kg and weight of the pulley can be reduced by about 0.4 kg with the result that overall weight may be reduced by about 0.8 kg.

First claim

What is claimed is:

1 . A plastic composite comprising an amount of about 20% by volume or greater of a magnetic alloy material on the basis of the total volume of the plastic composite.

2 . The plastic composite of claim 1 , wherein the magnetic alloy material is ferrite magnetic powder comprising iron, cobalt, nickel or alloys thereof.

3 . The plastic composite of claim 2 , wherein the magnetic alloy material further comprises a rare earth-based magnetic alloy powder.

4 . The plastic composite of claim 3 , wherein the rare earth-based magnetic alloy material comprises a rare earth-cobalt magnetic powder.

5 . An air conditioner compressor comprising:
a pulley comprising a plastic composite; and a clutch comprising a contact portion comprising the plastic composite in contact with a bottom-end surface of the pulley, wherein the plastic composite is disposed inside the pulley and comprises an amount of about 20% by volume or greater of a magnetic alloy material on the basis of the total volume of the plastic composite.

6 . The air conditioner compressor of claim 5 , wherein a thinnest portion of a surface area adjacent to an electromagnetic induction coil has a thickness of at least about 3 mm.

7 . The air conditioner compressor of claim 5 , wherein the plastic composite is formed inside a steel material and a shape of a cross-section area of the plastic composite comprises an upper end longer than a lower end.

8 . The air conditioner compressor of claim 7 , wherein the shape comprises an “I” shape of which the upper end is longer than the lower end, a “T” shape that is getting wider toward its lower end, or a “T” shape having a hexagonal shaped lower end.

9 . The air conditioner compressor of claim 5 , wherein the magnetic alloy material is ferrite magnetic powder comprising iron, cobalt, nickel or alloys thereof.

10 . The air conditioner compressor of claim 9 , wherein the magnetic alloy material further comprises a rare earth-based magnetic alloy powder.

11 . The air conditioner compressor of claim 10 , wherein the rare earth-based magnetic alloy material comprises a rare earth-cobalt magnetic powder.

12 . A method of producing an air conditioner compressor, comprising:
applying a plastic composite to a pulley of the air conditioner compressor; and applying the plastic composite to a clutch of the air conditioner compressor, wherein the plastic composite comprises an amount of about 20% by volume or greater of a magnetic alloy material on the basis of the total volume of the plastic composite.

13 . The method of claim 12 , further comprising,
preparing the pulley by laminating the plastic composite on an aluminum material.

14 . The method of claim 12 , further comprising,
preparing the clutch by laminating the plastic composite on a surface of a straight plane of a steel material.

15 . The method of claim 12 , further comprising,
preparing the clutch by forming dimples on a surface of the steel material and laminating the plastic composite on the dimpled surface of the steel material.

16 . The method of claim 15 , wherein the dimpled surface is formed by injecting steel balls or ceramic balls at high speed.

17 . The method of claim 14 , wherein the plastic composite is formed inside the steel material and a shape of a cross-section area of the plastic composite comprises an upper end longer than a lower end.

18 . The method of claim 17 , wherein the shape comprises an “I” shape of which the upper end is longer than the lower end, a “T” shape that is getting wider toward its lower end, or a “T” shape having a hexagonal shaped lower end.

19 . A vehicle comprising an air conditioner compressor manufactured by a method of claim 12 .

Assignees

• Hyundai Motor Co Ltd
• Kia Motors Corp

Inventors

• Kang Hee-Sam
• Jeong Tae-Ho

Classifications

• B22F1/10

  Metallic powder containing lubricating or binding agents; Metallic powder containing organic material · CPC title

• B29K2505/08

  Transition metals · CPC title

• F04B35/01

  the means being mechanical · CPC title

• B29C45/14311

  using means for bonding the coating to the articles (B29C45/14795 takes precedence) · CPC title

• H01F1/113

  in a bonding agent · CPC title