Annular Motor Contact Assembly With Air-Gap Insulation
Solution Overview
Problem
The existing assembly for establishing electrical contact with electric motors in vehicle air conditioning systems is complex, time-consuming, and prone to errors, requiring numerous components and long connection conductors, which increases material costs and weight.
Innovation Solution
An assembly with an annular carrier element formed by injection molding, integrating electrical conductor elements and overmolded with plastic, featuring radial and axial connection elements that reduce the number of components and assembly steps, ensuring hermetic sealing and direct electrical contact with the stator coils, and incorporating spacer elements to maintain an air gap for insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional plug connectors and separate components are used for establishing electrical contact, then reliable electrical connection is achieved, but assembly complexity and time increase significantly
Solution Approach 1:
The patent combines the plug connector housing, electrical contact elements, and insulation components into a single integrated connector assembly. This merging of previously separate components (plug housing, contact pins, insulation material) reduces assembly complexity while maintaining reliable electrical connections through the integrated design.
2Reliability
If multiple separate assembly steps are used for connecting lead wires and ensuring insulation, then proper electrical insulation is achieved, but assembly time and error potential increase
Solution Approach 1:
The connector assembly is pre-configured with electrical contact elements and insulation structures before installation. The housing and internal components are prepared in advance with proper positioning, allowing for rapid installation that maintains insulation reliability without requiring multiple separate assembly steps during final assembly.
Solution Approach 2:
The insulation material and electrical contact elements are integrated into a single connector unit, combining previously separate insulation and connection functions. This allows simultaneous achievement of electrical insulation and connection in a single assembly operation, improving productivity while maintaining reliability.
3Adaptability or versatility
If long connection conductors are used to connect the stator to the plug receptacle, then flexible routing is achieved, but material costs and weight increase
Solution Approach 1:
The connector assembly utilizes three-dimensional spatial arrangement to achieve flexible routing capabilities. By positioning contact elements and housing structures in multiple dimensions, the design provides routing adaptability without requiring excessive conductor length, thereby reducing weight while maintaining flexibility.
4Reliability
If additional insulation components and hermetic sealing elements are added, then electrical insulation and sealing are improved, but the number of components and assembly complexity increase
Solution Approach 1:
The hermetic sealing elements and insulation components are integrated into the connector housing structure itself. The housing design incorporates sealing features and insulation properties directly into its construction, eliminating the need for separate additional components while maintaining high sealing quality and electrical insulation.
Solution Approach 2:
The connector housing utilizes composite material construction that combines insulating and sealing properties in a single material system. This composite approach provides both hermetic sealing and electrical insulation functions through the material composition itself, reducing the need for additional separate components.
Data Source
AI summary
An assembly for establishing electrical contact with an electric motor for driving a compressor which is formed in a motor vehicle air conditioning system for compressing a gaseous fluid. The assembly has an annular carrier element, wherein the annular carrier element on its side facing the stator has at least two axial spacer elements, which rest on an axial end face of the stator when the assembly is positioned on the stator, wherein the spacer elements are dimensioned in such a way that an air gap is formed between an underside of the annular carrier element and an axial end face of the stator. The invention also relates to a method for assembling the assembly, and an electric motor having such an assembly.