Compressor Connector Terminal Fixing via Plastic Deformation
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Solution Overview
Problem
The manufacturing process of connectors for electromagnetic clutches in compressors is inefficient due to the need for additional processes and increased production costs caused by the separate injection of thermosetting resin to fix electric parts, and there is a risk of bad connections from exposure of surge absorbing devices before assembly.
Innovation Solution
The method involves arranging lead wires of electric parts in coupling slots of terminals, plastically deforming slot bridges to fix them, and assembling the connector through injection molding, which integrates the surge absorbing circuit and terminals, eliminating the need for a separate resin injection process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If thermosetting resin is injected separately to fix electric parts in the connector, then the electric parts are securely fixed, but the number of manufacturing processes increases and production time is extended
Solution Approach 1:
The patent combines the electric part fixing function with the connector housing material itself. The housing is designed with embedded fixing protrusions that directly secure the electric parts during the injection molding process, eliminating the need for separate resin injection. This merging of functions reduces the number of manufacturing steps while maintaining secure fixation.
Solution Approach 2:
The fixing structure is designed and prepared in advance as an integral part of the connector housing. The fixing protrusions are formed during the initial injection molding of the housing, before the electric parts are installed. This preliminary preparation of the fixing structure eliminates the need for subsequent resin injection operations.
2Reliability
If thermosetting resin is used to fix the surge absorbing circuit, then the circuit is securely mounted, but additional production time is required for resin solidification
Solution Approach 1:
The housing material itself is designed to provide the fixing function, combining the structural support and mounting functions into a single component. The embedding of electric parts within the housing structure during injection molding eliminates the need for separate resin solidification time.
Solution Approach 2:
The injection molding process continuously forms both the housing structure and the fixing protrusions in a single operation. The electric parts are secured during this continuous process without interruption for resin injection or solidification, maintaining continuous productive action throughout manufacturing.
3Ease of manufacture
If the surge absorbing device is exposed before assembly, then it can be easily installed, but it is vulnerable to foreign substance contamination causing bad connections
Solution Approach 1:
The electric parts are nested within the housing structure during the injection molding process. The housing cavity serves as a protective enclosure that guides and secures the electric parts in their correct positions, protecting them from contamination while enabling precise installation.
Solution Approach 2:
The housing is pre-formed with integrated guiding structures and fixing protrusions that automatically position and secure the electric parts during assembly. This preliminary preparation of the housing structure enables easy and contamination-free installation of the surge absorbing circuit.
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
This approach reduces the number of manufacturing processes, decreases production time, and shields the connections from foreign substances, enhancing the reliability and efficiency of the connector assembly.
Implementation Method 1
making the connector in a state where the terminal is fixed to an assembly of at least the discharge device or remaining magnetic field removing device by injection molding
Implementation Method 2
plastically deforming at least one slot bridge to fix the lead wire to the coupling slot
Data Source
AI summary
The present invention relates to a connector of an electromagnetic clutch for a compressor and a manufacturing method thereof. The method includes the steps of arranging a leading end of a lead wire 62 or 72 of at least one discharge device 60 or remaining magnetic field removing device 70, which configures a surge absorbing circuit, to a terminal 50 installed in a connector 30 configuring a field coil assembly and having a coupling slot 56 formed in one side thereof; plastically deforming at least one slot bridge 57 to fix the lead wire 62 or 72 to the coupling slot 56; and making the connector 30 in a state where the terminal 50 is fixed to an assembly of at least the discharge device 60 or remaining magnetic field removing device 70 by injection molding.