Compressor Drive Plug Housing Hermetic Sealing
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Solution Overview
Problem
Conventional electric motors for compressors in climate control systems of motor vehicles face challenges in simple and time-saving assembly, with complex sealing requirements and additional securement elements needed to prevent fluid penetration and short circuits, while also aiming to minimize weight and production costs.
Innovation Solution
A device comprising a rotor and stator with lacquer-coated copper wire conductor segments, where the plug housing is integrated with a support element and filled with a potting compound for hermetic sealing, reducing the need for additional sealing elements and securement means, and featuring a multifunctional support element with guide members and pressure members for precise positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional plug housings are pressed onto stator insulation with separate sealing elements, then hermetic sealing is achieved, but device complexity and assembly time increase
Solution Approach 1:
The sealing function is merged with the plug housing structure itself. The plug housing includes an integrated sealing bead that directly contacts the stator insulation, eliminating the need for separate sealing elements like O-rings or gaskets. This integration reduces the number of components and simplifies assembly while maintaining hermetic sealing.
Solution Approach 2:
The plug housing serves multiple functions simultaneously: it provides mechanical support for electrical connections, ensures hermetic sealing through the integrated sealing bead, and positions the connector pins. This multi-functionality reduces the need for additional separate components and simplifies the overall assembly.
2Reliability
If multiple separate sealing elements are used to prevent fluid penetration, then sealing reliability is improved, but weight and production costs increase
Solution Approach 1:
The sealing function is combined into the plug housing structure itself through an integrated sealing bead, eliminating the need for multiple separate sealing elements. This integration reduces the total material usage and device weight while maintaining effective sealing against refrigerant fluid penetration.
3Stability of the object's composition
If additional securement elements are used to prevent displacement, then connection stability is improved, but assembly time and device complexity increase
Solution Approach 1:
The securing function is merged with the plug housing structure. The housing includes integrated features such as engagement protrusions or interference-fit designs that automatically secure the plug housing to the stator insulation upon assembly, eliminating the need for additional separate securement elements like clips or fasteners.
4Ease of manufacture
If conventional pressing assembly is used, then assembly is simplified, but positioning precision and hermetic sealing are compromised
Solution Approach 1:
The plug housing is designed with pre-formed sealing beads and integrated positioning features that are created during the housing manufacturing process. These pre-prepared features ensure correct positioning and hermetic sealing upon assembly without requiring complex assembly operations or additional adjustment steps.
Data Source
AI summary
Device for driving a compressor of a gaseous fluid having a rotor and a stator disposed extending along a common longitudinal axis. The stator comprises connection leads implemented as segments of conductor wires of coils. The device has a plug housing for receiving a connecting element which is electrically connected with a connection lead of a conductor wire with a plug connector. Support element is disposed on the stator with a receiving member for the plug housing. Receiving member comprises a connecting passage and plug housing is slid into the receiving member in such manner and disposed in the receiving member such that in each instance one connecting passage of the receiving member and the connecting element for receiving a plug connector correspond. Plug housing is filled at least in regions with potting compound and connected with support element under hermetic seal. Methods for assembling the device are provided.