Compressor Connector Dielectric Barrier Against PAG Oil
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Solution Overview
Problem
Existing electrical connection devices for compressors in refrigerant circuits of motor vehicles face challenges in preventing electrical leaks, particularly when in contact with PAG oil, due to high electrical potentials, which can lead to serious damage.
Innovation Solution
A one-piece dielectric connector with elastomeric material is used to create a barrier between connection terminals and the compressor walls, featuring aligned orifices, holes, and recesses that form conduits for terminals, increasing insulation and moving terminals away from the walls, thus preventing electrical conductivity and oil spread.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional electrical connection devices are used in compressor environments with PAG oil, then electrical connections can be established, but electrical leaks occur due to high electrical potentials and oil conductivity
Solution Approach 1:
A dielectric element is introduced as an intermediary component between the electrical connection terminals and the compressor housing wall. This dielectric element prevents direct electrical contact through the PAG oil, blocking the harmful electrical leakage path while allowing the electrical connection to function. The dielectric material's insulating properties create a safe barrier that maintains electrical isolation even in the presence of conductive PAG oil.
Solution Approach 2:
The invention adds a dimensional aspect to the connection structure by extending the dielectric element to bridge the gap between the connection terminals and the housing wall. Instead of relying solely on lateral spacing, the dielectric element creates a third-dimensional barrier that spans the oil-filled space, preventing electrical discharge through the oil medium.
2Volume of moving object
If connection terminals are positioned close to the compressor housing wall, then the connector size is reduced, but electrical leaks increase due to PAG oil spreading between the wall and terminals
Solution Approach 1:
The dielectric element serves as a mediator that allows connection terminals to be positioned closer to the housing wall without creating electrical leakage paths. By inserting this insulating barrier between the terminals and the wall, the design can minimize connector volume while maintaining electrical isolation, as the dielectric prevents PAG oil from establishing conductive paths.
Solution Approach 2:
The dielectric element functions as a thin film or barrier that separates the electrical connection area from the housing wall. This thin insulating layer effectively blocks the spread of PAG oil between the wall and terminals, maintaining electrical isolation while occupying minimal space and allowing compact connector design.
3Reliability
If multiple components are used to create electrical insulation, then insulation performance is improved, but device complexity increases
Solution Approach 1:
The invention combines multiple insulation functions into a single integrated dielectric element. Instead of using separate insulation components, spacers, and barriers, one monolithic dielectric element performs all necessary insulation tasks: isolating terminals from the housing wall, preventing oil leakage paths, and maintaining electrical separation. This merging approach simplifies the connector structure while achieving the required insulation performance.
Solution Approach 2:
The dielectric element is designed to perform multiple functions simultaneously: it provides electrical insulation, prevents PAG oil from creating leakage paths, maintains spacing between components, and structurally supports the connection terminals. This multi-functionality reduces the overall component count and simplifies the connector design while ensuring reliable electrical isolation.
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 effectively reduces electrical leaks and enhances insulation performance, ensuring safe and reliable connections between electric motors and control modules in compressors, preventing damage from PAG oil and high electrical potentials.
Implementation Method 1
The one-piece dielectric element forms a barrier which significantly reduces the electrical leaks between the terminal(s) present in the connector and the wall of the compressor surrounding the connection terminals
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
The invention relates to a connector (100) between an electric motor and a control module, comprising a base (1) in which are provided, on the one hand, receiving recesses (10a, 10b, 10c) configured to receive a lug (4) for connection to terminals (5a, 5b, 5c) of the control module and, on the other hand, openings (11a, 11b, 11c) for the passage of said terminals (5a, 5b, 5c), a straight line (110) passing through said openings (11a, 11b, 11c), the connector (100) comprising a cover (2) at least a portion (200) of which is an extension of the recesses (10a, 10b, 10c) and a portion (210) in which are provided holes (21a, 21b, 21c) aligned with the ports (11a, 11b, 11c), characterized in that the connector (100) comprises at least one monobloc dielectric element (3) aligned with the ports (11a, 11b, 11c) and housed between the base (1) and the cover (2).