Compressor Plug Assembly with Glass Fiber Reinforced Outer Body
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Solution Overview
Problem
Existing compressor terminal assemblies face challenges in providing a reliable and flame-resistant electrical connection while maintaining a hermetic seal, as flexible materials used in plugs are not sufficiently rigid or durable, and existing solutions do not adequately address the need for a secure, flame-resistant, and non-flexible plug assembly.
Innovation Solution
A compressor plug assembly featuring a rigid and non-flexible thermoset or thermoplastic material with an inner core and outer body, including glass fibers, which provides a flame-resistant and durable connection through a dual-body structure with an annular sealing member, ensuring electrical communication and hermetic sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If flexible material is used for the plug, then ease of installation is improved, but structural strength and flame resistance deteriorate
Solution Approach 1:
The plug assembly uses a composite structure with an inner core made of flexible material (thermoplastic elastomer or silicone rubber) surrounded by an outer body made of rigid flame-resistant material (thermoset or thermoplastic with 30% glass fibers). This composite structure combines the advantages of both materials: the inner core provides ease of installation and flexibility, while the outer body provides structural strength and flame resistance.
2Strength
If rigid material is used for the plug, then structural strength is improved, but ease of installation and hermetic sealing deteriorate
Solution Approach 1:
The dual-material construction allows the inner core to remain flexible for easy installation and sealing, while the outer rigid shell provides the necessary structural strength and flame resistance. The flexible inner core can deform during insertion to engage with the terminal body, then regain its shape to maintain the hermetic seal.
Solution Approach 2:
The plug is divided into two functional segments: an inner core responsible for flexibility and sealing, and an outer body responsible for structural strength and flame resistance. This segmentation allows each part to optimize its specific function without compromising the other.
3Reliability
If flame-resistant material is used, then safety is improved, but flexibility and ease of installation deteriorate
Solution Approach 1:
The outer body is constructed from flame-resistant thermoset or thermoplastic material containing 30% glass fibers, providing safety and flame resistance. The inner core uses flexible thermoplastic elastomer or silicone rubber, enabling ease of installation. Together, they create a plug that is both safe and easy to install.
4Object-affected harmful factors
If hermetic seal is implemented, then protection against moisture and debris is improved, but device complexity increases
Solution Approach 1:
The flexible inner core automatically forms a hermetic seal through its elastic properties when the plug is inserted into the terminal body. The material deforms to fill gaps and then maintains constant contact pressure, creating a self-sealing mechanism that protects against moisture and debris without requiring additional sealing components.
Data Source
Figure 1~3
Figure 4~6
AI summary
A plug assembly for a compressor having a shell, a terminal body on the shell, and a conductor pin extending through the terminal body, wherein a connector body of the plug assembly includes a plurality of electrical receptacles for electrical communication with the conductor pin at least partially disposed within a fence disposed around the terminal body. The plug assembly may be formed of a thermoplastic or thermoset material having a tensile modulus between 9500 MPa and 18000 MPa, and/or about 30 percent glass fibers. At least one electrical receptacle may be housed by an inner core of the plug assembly for electrical communication with the conductor pin. An annular sealing member may be supported by an outer body of the plug assembly for sealingly engaging the fence.