Motor-Driven Compressor Terminal Sealing Without Press-Fitting

Solution Overview

Problem

The existing motor-driven compressors face challenges in maintaining sealing performance at the circumferential surface of tubes due to deformation and displacement of seal members during the press-fitting process, which can reduce the sealing effectiveness.

Innovation Solution

The design incorporates a terminal holder with a lid that closes the opening of the cluster block, featuring a guide recess and cutout to receive the tube, ensuring the outer circumferential surface of the tube conforms to the inner surface, and uses seal members to restrict refrigerant entry, eliminating the need for press-fitting and thus preventing deformation or displacement of the seal member.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the seal member is press-fitted into the connector housing to close the clearance between motor leads and connector housing, then the sealing performance is improved, but the seal member may be deformed or displaced during the press-fitting process, reducing sealing performance

Engineering Contradiction:

Improvesealing performanceVSAvoiddifficulty of press-fitting process

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

A seal member is introduced as an intermediary element between the motor leads and the connector housing. This seal member is specifically designed to be received by a seal member receiving structure that includes a seal member receiving groove and a seal member receiving protrusion, which guides and constrains the seal member during assembly, preventing deformation and displacement while ensuring reliable sealing of the clearance.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The seal member receiving structure is pre-formed in the connector housing with precise geometry (groove and protrusion configuration) that anticipates the seal member's insertion. This preliminary preparation ensures that when the seal member is installed, it is automatically guided into the correct position and orientation, preventing displacement and deformation during the assembly process.

Inventive Principle:

Principle #10Preliminary action

2Reliability

If the seal member is press-fitted to ensure sealing, then sealing performance is improved, but the process becomes complex and time-consuming

Engineering Contradiction:

Improvesealing performanceVSAvoidassembly process efficiency

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The seal member receiving structure is pre-formed in the connector housing with precise geometry (groove and protrusion configuration) that anticipates the seal member's insertion. This preliminary preparation ensures that when the seal member is installed, it is automatically guided into the correct position and orientation, preventing displacement and deformation during the assembly process.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

A seal member is introduced as an intermediary element between the motor leads and the connector housing. This seal member is specifically designed to be received by a seal member receiving structure that includes a seal member receiving groove and a seal member receiving protrusion, which guides and constrains the seal member during assembly, preventing deformation and displacement while ensuring reliable sealing of the clearance.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Shape

If the tube is received by the cutout in the lid, then the outer circumferential surface of the tube conforms to the inner surface, but refrigerant may still enter through the opening

Engineering Contradiction:

Improveconformance of tube surfaceVSAvoidrefrigerant entry

Core Design Contradiction:

ShapeVSObject-affected harmful factors

Solution Approach 1:

A seal member is introduced as an intermediary element between the motor leads and the connector housing. This seal member is specifically designed to be received by a seal member receiving structure that includes a seal member receiving groove and a seal member receiving protrusion, which guides and constrains the seal member during assembly, preventing deformation and displacement while ensuring reliable sealing of the clearance.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The sealing function is extracted from the lid structure itself and implemented through a separate, dedicated seal member that is received by the lid. This allows the lid's primary function (closing the opening) to be separated from the sealing function, which is specifically handled by the seal member in the receiving structure, ensuring both structural integrity and effective sealing.

Inventive Principle:

Principle #2Taking out (Extraction)

Data Source

PatentUS11855503B2Motor-driven compressor

Publication Date: 2023.12.26 TOYOTA INDUSTRIES CORP

AI summary

A motor-driven compressor includes a plurality of motor wires and an insulating terminal container. The motor wires include portions covered with an insulating tube and distal ends at which a connection terminal is provided. The terminal container includes a cluster block and a terminal holder. The cluster block accommodates the connection terminal and has an opening. The terminal holder holds the connection terminal and has a lid that closes the opening. The cluster block includes a base portion. The lid has a cutout that receives the tube. The lid is in contact with the base portion such that a part of a hole defined by the cutout is closed by the base portion.