Integrated Plug Connector Assembly for Hermetic Compressor Housing
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Solution Overview
Problem
Existing compressor systems for air conditioning in motor vehicles require complex and time-consuming installation processes due to numerous components, leading to increased material and production costs, as well as limited installation space for plug connectors and interlock connections.
Innovation Solution
A unified, one-piece receiving element integrates both low-voltage and high-voltage plug connectors and an interlock connection, providing hermetic sealing and reducing the number of components and installation complexity by pre-assembling the connections within a cohesive unit, which can be easily inserted into the housing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate plug connections are used for low-voltage and high-voltage ranges, then electrical energy transmission is achieved, but the number of components and installation complexity increases
Solution Approach 1:
The patent combines separate low-voltage and high-voltage plug connections into a single integrated plug connector assembly. This merging reduces the total number of components while maintaining reliable electrical energy transmission for both voltage ranges through a unified structure that accommodates multiple electrical connections.
Solution Approach 2:
The integrated plug connector serves multiple functions simultaneously: it handles both low-voltage and high-voltage electrical connections, provides hermetic sealing for all connections, and incorporates interlock mechanisms. This multi-functionality eliminates the need for separate dedicated connectors for each voltage range.
2Reliability
If multiple separate plug connections are installed, then electrical connections are established, but installation time and production costs increase
Solution Approach 1:
The plug connector is pre-assembled as an integrated unit with all low-voltage and high-voltage connections, sealing elements, and interlock mechanisms already in place. This preliminary assembly allows the entire connector assembly to be installed as a single component, dramatically reducing installation time compared to assembling multiple separate connections on-site.
Solution Approach 2:
By merging multiple separate plug connections into one integrated assembly, the installation process is simplified from multiple separate installation steps to a single installation action, reducing both installation time and production costs while maintaining all necessary electrical connections.
3Reliability
If separate plug connections with multiple sealing elements are used, then hermetic sealing is achieved, but the number of components and material costs increase
Solution Approach 1:
The patent integrates multiple sealing functions into a unified plug connector structure. Instead of using separate sealing elements for each individual connection, the design incorporates a consolidated sealing system that provides hermetic sealing for all low-voltage and high-voltage connections simultaneously, reducing material usage and manufacturing complexity.
4Reliability
If plug connectors are installed in limited housing space, then electrical connections are made, but installation complexity increases due to space constraints
Solution Approach 1:
The integrated plug connector design nests multiple electrical connections (low-voltage and high-voltage) within a single compact assembly structure. This nesting approach allows all necessary connections to be accommodated in a space-efficient manner, fitting into the limited housing space of the compressor while maintaining installation simplicity.
Data Source
AI summary
An arrangement for plug connecting electrical connections through a housing, particularly a device for driving a compressor. The arrangement includes a first plug connection having first plug connectors and a second plug connection having second plug connectors for transmitting electrical energy in independent transmitting ranges and a receiving element for receiving plug connectors. The receiving element having first plug connectors of the first plug connection and second plug connectors of the second plug connection is thereby implemented as an integral and cohesive unit and one-piece component.