Electric Compressor Sealed Terminal Labyrinth Mechanism
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Solution Overview
Problem
In electric compressors, the circulation of refrigerant between the sealed terminal and the cluster block leads to the collection of abrasive particles, which can cause short-circuiting between the terminal and the housing due to wear particles and metal debris, resulting in electrical leakage.
Innovation Solution
A labyrinth mechanism is created by protrusions around the insulative bodies of the terminal pins and cluster block, which obstructs the flow of refrigerant and prevents abrasive particles from reaching the insulative bodies, ensuring that the terminal pins and holder remain free from deposition and short-circuiting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the cluster block is spaced apart from the sealed terminal, then the structure in the motor housing is simpler and there is no need for special fastening means, but refrigerant freely circulates between the sealed terminal and the cluster block causing abrasive particles to collect on the insulative material and cause short-circuiting
Solution Approach 1:
A labyrinth structure is introduced as an intermediary element between the sealed terminal and the cluster block. This labyrinth structure serves as a mediator that allows the spaced-apart arrangement to maintain simplicity while preventing direct refrigerant circulation between the components, thus avoiding particle accumulation and short-circuiting risks
Solution Approach 2:
The harmful refrigerant circulation path is extracted and eliminated by introducing the labyrinth structure. The labyrinth structure separates the refrigerant flow paths, preventing refrigerant from freely circulating between the sealed terminal and cluster block, thereby removing the source of particle accumulation without requiring complex fastening mechanisms
2Ease of manufacture
If abrasive particles enter and collect in fine pores of the ceramic insulator, then the insulator becomes contaminated with particles, but this causes short-circuiting between the connection terminal and the terminal body
Solution Approach 1:
The labyrinth structure acts as an intermediary barrier that prevents abrasive particles from reaching the ceramic insulator. By interposing this structural element between the refrigerant flow path and the insulator, the system maintains manufacturing simplicity while effectively blocking particle contamination of the insulative material
Data Source
AI summary
An electric compressor including a compression mechanism, an electric motor, an inverter, a compressor housing, a sealed terminal, a cluster block, and a metal brace. The sealed terminal is arranged in the compressor housing and electrically connects the inverter and the electric motor. Further, the sealed terminal includes a terminal pin, which is formed from a conductive material, a terminal holder, and an insulative body. The cluster block includes an insertion hole into which the terminal pin is inserted. The metal brace electrically connects the terminal pin to the lead wire. The cluster block includes a protrusion projecting around the insertion hole and surrounding part of the insulative body. The insertion hole has an inside diameter larger than an outside diameter of the terminal pin.