Magnetic Alloy Plastic Composite for Air Conditioner Compressor Weight Reduction
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Solution Overview
Problem
Clutch type variable air conditioner compressors with steel pulleys and clutches are heavy and costly due to the inclusion of electromagnetic induction coils and magnetized steel, which increases unnecessary power consumption when the air conditioner is not in use.
Innovation Solution
A plastic composite with a magnetic alloy material, including ferrite and rare earth-based magnetic powders, is used to replace steel components, reducing weight and cost by enabling efficient magnetic field transmission and eliminating the need for a frictional material, while maintaining driving efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If steel pulley and steel clutch are used in clutch type variable compressor, then magnetic field transmission is effective for clutch operation, but weight increases and cost increases
Solution Approach 1:
The patent uses a composite material consisting of aluminum (non-magnetic, lightweight) as the base material and iron powder (magnetic material) as the reinforcement. This composite provides both the lightweight property of aluminum and the magnetic properties needed for clutch operation, resolving the contradiction between weight reduction and magnetic field transmission effectiveness
Solution Approach 2:
The patent changes the material parameters by controlling the iron powder content (2-10 wt%), particle size (10-100 μm), and distribution within the aluminum matrix. By optimizing these parameters, the composite achieves sufficient magnetic permeability for clutch operation while maintaining the lightweight advantage of aluminum
2Use of energy by moving object
If electromagnetic induction coil and steel clutch are added to increase driving efficiency, then power consumption is reduced when air conditioner is not in use, but weight and cost increase
Solution Approach 1:
The patent creates a magnetic field transmission pathway using the aluminum-iron powder composite that replicates the magnetic properties of solid steel components. This allows the electromagnetic induction coil to effectively operate the clutch without requiring heavy steel materials, thus reducing weight while maintaining energy efficiency
3Reliability
If steel material is used for pulley and clutch, then magnetic properties are sufficient for electromagnetic clutch operation, but manufacturing cost increases
Solution Approach 1:
The patent replaces expensive solid steel components with a more cost-effective aluminum-iron powder composite. The composite material is cheaper to manufacture while providing sufficient magnetic properties for clutch operation, thus reducing manufacturing cost without sacrificing functional reliability
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution reduces the overall weight of the compressor by approximately 0.8 kg, minimizes shock noise, and lowers manufacturing costs by downsizing components and eliminating unnecessary power consumption.
Implementation Method 1
The magnetic alloy material includes a powder and transmits magnetic field induced by the electromagnetic induction coil
Implementation Method 2
the steel clutch is operated by magnetic field induced by the electromagnetic induction coil
Data Source
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AI summary
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.