Method and apparatus for sealing motor terminals
View Patent ↗A wire insulator apparatus includes an insulator/separator member, a cap portion, a tube and potting material. The insulator/separator member has apertures formed therein for receiving a plurality of wires. By threading the wires through the insulator/separator member, the wires are spaced apart so that a potting material can be molded to provide a complete seal from the environment, particularly conductive liquids such as ammonia, which may cause short-circuiting between the wires. Individual wires are terminated in the cap portion, and the cap portion, the insulator/separator member and the wire ends are positioned within a tube or a mold portion depending on the application, and a potting epoxy is fluidly inserted within the tube. The epoxy surrounds or encases the wire ends within the tube or mold to insulate the wire ends in an airtight seal.
1. A wire insulator for sealing motor terminals, comprising:
an insulator/separator member, a cap portion, a tube and potting epoxy;
the insulator/separator member comprising a plurality of apertures, the apertures configured for receiving and threading a plurality of wire strands through the insulator/separator member, wherein the plurality of wire strands are separated and insulated from adjacent wire strands to create a space for the potting epoxy to seal each of the wire strands from an environmental atmosphere;
the cap portion configured to terminate the wire strands; and
the tube surrounding the cap portion, the insulator/separator member, the potting epoxy, and at least a portion of the plurality of wire strands;
wherein each wire of the plurality of wire strands further comprises insulation and at least one end, and each wire of the plurality of wire strands is stripped of insulation at the at least one end to expose a conductor for termination inside the cap portion; and
a recessed stub portion, the cap portion insertable into the recessed stub portion;
and a stud member attached to the recessed stub portion;
the stud member mounted to an insulator board.
2. The wire insulator of claim 1 , wherein the tube is a shrink tube.
3. The wire insulator of claim 1 , wherein the plurality of wire strands extends from inside of a motor or compressor housing.
4. The wire insulator of claim 1 , wherein lead wire strands pass through the insulator/separator and are connected to a lead wire or multi-conductor cable at a connection point.
5. The wire insulator of claim 1 , wherein the plurality of wire strands is soldered or crimped to the lead wires.
6. The wire insulator of claim 1 , wherein the tube comprises a hollow insulating tube, and the plurality of wire strands are threaded through the tube prior to the tube being positioned over the cap portion, the insulator/separator member, the potting epoxy, and the wire ends.
7. The wire insulator of claim 1 , wherein the potting material is selected from epoxy, urethane, silicone or other suitable potting material.
8. The wire insulator of claim 1 , wherein the insulator/separator member is a cylindrical, solid block insulator; and wherein the wire strands are threaded through the passages traversing through the insulator/separator member.
9. The wire insulator of claim 1 , wherein the stud member further comprises a hexagonal nut portion configured to receive a wrench, the nut threadably attached to the stud member for securing the recessed stub portion on the stud member.
10. A wire insulator comprising:
an insulator/separator member, a cap portion, a hollow mold portion and potting epoxy;
the mold portion enclosing, the insulator insulator/separator member, and the cap portion, and a plurality of lead wire strands;
the mold portion comprising a first end and a second end,
the mold portion open at the first end and attached to an insulator board at the second end;
the insulator board attached to a stud member for mounting a stud member to the compressor or motor housing; and the potting epoxy infused into the mold portion to provide an airtight seal;
the lead wires soldered or crimped in the cap portion;
and a recessed stub portion to receive the cap portion; the stub portion attached to one end of the stud member.
11. The wire insulator of claim 10 , wherein the lead wire strands comprise Teflon-coated copper wire strands.
12. The wire insulator of claim 10 , wherein the lead wire strands comprise aluminum wire stands.
13. The wire insulator of claim 10 , wherein the lead wire strands comprise insulated coatings.
14. The wire insulator of claim 10 , wherein the insulator/separator separates the wire strands to provide space for the potting material in liquid form to flow around the wire strands prior to curing, to insulate the insulator/separator member, at least one end of the wire strands, and the cap portion.