Compressor Plug Assembly Hermetic Seal Design
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Solution Overview
Problem
Compressor terminal assemblies face challenges in providing a reliable and hermetic electrical connection while protecting conductor pins from damage and ensuring a secure, sealed interface with a plug assembly, which is not adequately addressed by existing designs.
Innovation Solution
A compressor design featuring a terminal body with conductor pins, a fence, and a plug assembly with an inner core and outer body made from rigid thermoset or thermoplastic materials, including a seal and retainer mechanism for secure engagement and protection, along with a method of manufacturing using injection molding and overmolding processes to ensure a durable and hermetic seal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a terminal assembly is designed to provide hermetic electrical connection, then reliability of electrical connection is improved, but device complexity increases due to multiple components (fence, seal, retainer, inner core, outer body)
Solution Approach 1:
The patent combines multiple protective and sealing functions into an integrated terminal assembly structure. The outer body and inner core are molded as integrated components that work together with the seal and retainer to provide hermetic sealing, electrical connection, and mechanical protection simultaneously, reducing the need for additional separate components.
Solution Approach 2:
The terminal assembly components serve multiple functions: the outer body provides structural support and electrical insulation, the inner core provides electrical connection pathways, the seal provides hermetic sealing, and the retainer provides mechanical retention. Each component is designed to perform multiple roles within the assembly, improving reliability without proportionally increasing complexity.
2Reliability
If conductor pins are protected from damage through enclosed structure, then reliability is improved, but ease of manufacture decreases due to complex molding processes
Solution Approach 1:
The conductor pins are pre-positioned and secured within the inner core structure before the outer body is molded over them. This preliminary action ensures proper positioning and protection of the conductor pins while simplifying the final assembly process, as the pins are already in their correct positions when the protective outer body is formed.
Solution Approach 2:
The terminal assembly uses a nested structure where the conductor pins are housed within the inner core, which is in turn housed within the outer body. This nested arrangement provides progressive protection at each level while allowing for efficient manufacturing through sequential molding processes where each layer is formed around the previous one.
3Strength
If rigid thermoset or thermoplastic materials are used for inner core and outer body, then strength and flame resistance are improved, but adaptability decreases due to material selection constraints
Solution Approach 1:
The patent specifies rigid thermoset or thermoplastic materials with particular properties (flame resistance, electrical insulation, rigidity) for the inner core and outer body. These material parameter specifications ensure consistent performance and reliability while allowing selection from multiple material types that meet the required criteria, maintaining adaptability within defined performance boundaries.
Solution Approach 2:
The terminal assembly uses composite construction with the inner core and outer body made from rigid thermoset or thermoplastic materials that combine multiple properties: structural strength, flame resistance, and electrical insulation. These composite materials provide enhanced performance while maintaining design flexibility through selection of different material formulations that meet the specified requirements.
4Reliability
If seal is mechanically and chemically attached to outer body, then hermetic seal reliability is improved, but manufacturing precision requirements increase
Solution Approach 1:
The seal is designed to provide both mechanical and chemical attachment to the outer body simultaneously. This combined attachment mechanism distributes the bonding requirements across multiple interaction modes, reducing the precision demand on any single attachment point while ensuring reliable hermetic sealing through the synergistic effect of both attachment types.
Data Source
AI summary
A compressor including a shell, a compression mechanism disposed within the shell, a motor actuating the compression mechanism, and a terminal body secured to the shell, may further include at least one conductor pin extending through the terminal body and a fence disposed around the terminal body and secured to the shell. A plug assembly having an inner core surrounded by an outer body includes at least one electrical receptacle housed by the inner core for selective electrical communication with the at least one conductor pin. A seal may be integrally formed with the outer body and may engage the fence when the at least one electrical receptacle is in electrical communication with the at least one conductor pin.