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The automotive industry has increasingly been focusing its efforts on vehicle part weight reduction, with the aim of improving fuel efficiency as an environmental protection measure. As part of these efforts, the industry has actively been developing plastic pulleys to replace conventional steel pulleys. Of the various pulleys used in vehicles, the air conditioner (A/C) compressor pulley is exposed to the harshest working environment. We therefore investigated towards development of a plastic pulley for A/C compressor application. Required material properties were first identified on the basis of required product characteristic values. As a result, a phenolic resin material was developed that is superior in heat resistance one of the most important properties among those identified. Using the material, we succeeded in developing an A/C compressor plastic pulley, achieving approximately 50% weight reduction compared to conventional steel pulleys.

We have developed a plastic pulley for automobiles, manufactured by injection molding which will reduce manufacturing cost. We have developed product design, injection molding technology especially to improve mechanical strength and phenolic molding compound with good wear resistance and high mechanical strength. We have established “Injection Compression molding” technology to improve mechanical strength of the welded portion. We have also developed a phenolic molding compound which is composed of one step resin and long organic fiber to obtain good wear resistance and high mechanical strength. Manufacturing cost will be reduced by using injection molding combined with lower material cost of the newly developed compound.