Control Card Assembly on Hermetic Compressor Cooling Plate
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Solution Overview
Problem
The assembly of control cards in variable frequency hermetic compressors is prone to faulty assembly and heat-related malfunctions due to dimensional changes and heat generation, leading to increased costs and reduced product quality.
Innovation Solution
A method involving a case with a base plate and side walls forming a channel, where a cooling plate with a protrusion and recesses is slidably mounted to ensure precise positioning without contact, using high heat conductivity materials and insulating materials to prevent short circuits, and additional features like stabilizers and ribs to secure the cooling plate, reducing manufacturing defects and vibrations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the cooling plate is closely positioned to the control card to dissipate heat effectively, then heat dissipation efficiency is improved, but the risk of electrical short circuit increases
Solution Approach 1:
An electrically insulating material is introduced as an intermediary layer between the cooling plate and the control card. This mediator allows thermal energy to transfer from the control card to the cooling plate while blocking electrical current, thus resolving the contradiction between effective heat dissipation and electrical safety.
2Stability of the object's composition
If traditional assembly methods are used to attach the cooling plate, then structural stability is achieved, but assembly complexity and manufacturing defects increase
Solution Approach 1:
The assembly structure is segmented into distinct functional elements: a base plate with protrusions, cooling plates with corresponding recesses, and connecting tabs. This segmentation allows each component to be manufactured independently and then assembled through simple insertion and sliding movements, reducing overall assembly complexity while maintaining stability.
Solution Approach 2:
The base plate is pre-formed with protrusions and the cooling plate with recesses during manufacturing. This preliminary preparation of mating surfaces enables the cooling plate to be automatically positioned and secured through a simple sliding insertion motion, eliminating the need for complex alignment procedures or additional fastening operations.
3Reliability
If the cooling plate is securely fixed to prevent movement, then assembly reliability is improved, but the risk of dimensional changes and assembly faults increases
Solution Approach 1:
The connection between the base plate and cooling plate is designed to be dynamically adaptable. The protrusions and recesses provide initial guidance and positioning, while the sliding insertion motion allows for automatic adjustment and accommodation of minor dimensional variations. This dynamic assembly process ensures reliable connection without compromising dimensional stability.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method simplifies assembly, reduces labor and manufacturing costs, prevents faulty assembly issues, and extends the lifespan of control cards and compressors by ensuring effective heat dissipation and secure attachment of the cooling plate.
Implementation Method 1
The cooling plate is made of a metal with high heat conductivity, therefore it is vital for the cooling plate to be closely positioned to the control card
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
The present invention relates to a method of assembling a control card (1) on to a cooling plate (11) of a hermetic compressor, comprising providing a case (2) having a base plate (3); having a first side wall (5) and a second side wall (6) having a first connecting tab (7) and a second connecting tab (8) respectively, extending parallel to the base plate (3) and forming a channel (9) thereinbetween; having a protrusion (4) and a rear wall (10) extending between said side walls (5,6); providing the cooling plate (11) having an aperture (12) and at least one recess (13) provided on an edge (14) of the cooling plate (11); attaching the cooling plate (11) to the base plate (3) via the aperture (12) through which the protrusion (4) is inserted and wherein the recess (13) and connecting tabs (7,8) are vertically aligned; attaching the cooling plate (11) by slidably moving on to the protrusion (4) along the aperture (12) and inside the channel (9) along the edge (14) simultaneously towards the rear wall (10).