Metal Terminal Cover Assembly for Compressor Fire and Explosion Risk

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Solution Overview

Problem

Conventional terminal covers for air conditioner compressors are vulnerable to fire due to their plastic injection molding, especially when using R290 refrigerant, which increases the risk of explosion and requires high levels of waterproofing, dustproofing, and fireproofing for safety.

Innovation Solution

A terminal cover assembly for the compressor, comprising a metal terminal cover with a gasket and screws, a cover body forming a terminal and cable accommodating portion, and a cover flange seated on a gasket, which minimizes the risk of explosion and fire spread by using a metal material and a sealed structure.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If plastic injection molding is used for terminal covers, then manufacturing cost and ease of manufacture are improved, but fire resistance and explosion risk are worsened

Engineering Contradiction:

Improveease of manufactureVSAvoidfire risk

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

The patent changes the material parameter of the terminal cover from plastic to metal (specifically aluminum alloy), fundamentally altering the fire resistance property while maintaining manufacturability through casting or forming processes

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The terminal cover assembly uses a composite structure combining metal terminal cover with rubber gasket, where the metal provides fire resistance and the rubber provides sealing, creating a composite solution that addresses both safety and functional requirements

Inventive Principle:

Principle #40Composite materials

2Ease of manufacture

If conventional plastic terminal covers are used, then manufacturing simplicity is improved, but waterproofing and dustproofing performance are worsened

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidwaterproofing performance

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent employs a composite structure where the metal terminal cover is combined with a rubber gasket. The gasket provides superior sealing properties for waterproofing and dustproofing, while the metal cover maintains manufacturing simplicity through forming processes

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent applies different material qualities to different parts: the metal terminal cover provides structural integrity and fire resistance, while the rubber gasket provides localized sealing quality at the interface, ensuring waterproofing without complicating the overall manufacturing

Inventive Principle:

Principle #3Local quality

3Object-affected harmful factors

If metal terminal cover is used, then fire resistance and explosion risk are improved, but manufacturing complexity and cost are worsened

Engineering Contradiction:

Improvefire resistanceVSAvoidmanufacturing complexity

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

The patent changes the material parameter from plastic to metal, improving fire resistance. The manufacturing complexity is managed by using standard metal forming or casting processes that are well-established in the industry

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The terminal cover assembly is segmented into the metal terminal cover and the rubber gasket as separate components. This segmentation allows each component to be manufactured using optimized processes for its material, with the gasket simplifying the sealing function without requiring complex integrated design

Inventive Principle:

Principle #1Segmentation

4Use of energy by moving object

If R290 refrigerant is used, then energy efficiency is improved, but explosion risk and safety requirements are worsened

Engineering Contradiction:

Improveenergy efficiencyVSAvoidexplosion risk

Core Design Contradiction:

Use of energy by moving objectVSObject-affected harmful factors

Solution Approach 1:

The patent addresses the safety issue of R290 refrigerant by changing the material parameter of the terminal cover to fire-resistant metal, creating a protective barrier that prevents ignition sources from compromising the flammable refrigerant system

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent converts the potential harm of using flammable R290 refrigerant into a benefit by implementing enhanced fireproofing measures. The metal terminal cover with gasket sealing creates a safer system that allows utilization of R290's high energy efficiency while mitigating its explosion risk through improved protective structures

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Data Source

PatentEP4644789B1Outdoor unit of air conditioner

Publication Date: 2026.04.15 LG ELECTRONICS INC

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AI summary

An outdoor unit of an air conditioner may include a compressor with a power terminal that protrudes from an upper surface thereof, and a terminal cover assembly coupled to the upper surface of the compressor to cover the power terminal. The terminal cover assembly may include a gasket disposed on the upper surface of the compressor; a terminal cover coupled to an upper surface of the gasket; and one or more fastening members that secures the gasket and the terminal cover to the compressor. The terminal cover may be formed of a metal material.