Refrigeration Compressor Terminal Insulator Curved Contour
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Solution Overview
Problem
Hermetically sealed electric conductive pins in terminal assemblies for refrigeration compressor motors face challenges in maintaining effective electrical insulation and sealing, which is crucial for safe and efficient operation under high pressures and voltages.
Innovation Solution
A terminal assembly design featuring an insulator with a convoluted contour, such as a washer with an annular recess, is used to increase the over-surface and through-space distances between the conductive pin and the terminal board, ensuring electrical insulation and sealing through the use of materials like synthetic resin or ceramic, and securing methods like torqueing or adhesives.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a simple insulator design is used, then manufacturing cost and device complexity are reduced, but electrical insulation effectiveness and sealing reliability deteriorate under high pressure and voltage conditions
Solution Approach 1:
The insulator employs a convoluted contour with curved, non-linear pathways instead of straight lines. This curvature increases the surface distance between conductive elements, providing enhanced electrical insulation effectiveness while maintaining a compact form factor suitable for hermetic compressor applications.
Solution Approach 2:
The insulator design transitions from a two-dimensional flat structure to a three-dimensional convoluted structure. By adding depth and complexity in the third dimension, the insulator achieves greater electrical insulation distance without proportionally increasing the overall footprint or manufacturing complexity.
2Reliability
If a simple insulator design is used, then manufacturing is easier, but sealing effectiveness against refrigerant leaks deteriorates under high pressure
Solution Approach 1:
The convoluted contour creates multiple contact surfaces and sealing interfaces between the insulator and housing. These curved surfaces conform better to mating surfaces, enhancing sealing effectiveness against refrigerant leaks while the overall geometry remains suitable for standard manufacturing processes.
3Reliability
If the distance between conductive pin and terminal board is increased, then electrical insulation is improved, but the overall assembly size increases
Solution Approach 1:
The insulator utilizes three-dimensional convoluted pathways to achieve extended electrical insulation distance within a compact volume. By routing through multiple dimensions and surfaces rather than simple linear extension, the design increases insulation effectiveness without proportionally increasing assembly size.
Solution Approach 2:
The convoluted insulator structure nests multiple functional pathways within a compact form. The complex contour allows the insulator to contain extended electrical pathways and sealing surfaces within a space-efficient geometry that fits within the hermetic compressor housing constraints.
Data Source
AI summary
A terminal assembly configured to conduct current from an external power source to a hermetical motor-compressor unit. The terminal assembly includes a terminal board, at least one opening defined through the thickness of the terminal board, at least a conductive pin received in the opening, and an insulator having a convoluted contour. The insulator may be disposed over the conductive pin and spaced away from the terminal board.