Capacitor for car AC generator

Details Capacitor for car AC generator Capacitor for car AC generator

1999-07-16

2001-05-22

Dinkins, Anthony (Department: 2831)

Electricity: electrical systems and devices

Electrostatic capacitors

Fixed capacitor

C361S306100

Reexamination Certificate

active

06236557

ABSTRACT:

BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a capacitor for a car AC generator, which comprises a capacitor element in the inside space of a generator case.
2. Description of the Prior Art
FIG. 9
is a sectional view of a car AC generator disclosed by Japanese Patent Publication No. 6-87646,
FIG. 10
is a front view of a capacitor disclosed by Japanese Laid-open Patent Application No. 7-213034, and
FIG. 11
is a sectional view cut on line E—E of FIG.
10
. In
FIG. 9
, reference numeral
1
denotes a generator case whose inside space is formed by fastening an aluminum front bracket
2
to an aluminum rear bracket
3
by a through bolt
4
in such a manner that they face each other. Denoted by
5
is a cylindrical stator composed of a core and a coil and supported by the inner wall of the front bracket
2
and the inner wall of the rear bracket
3
in the inside space of the generator case
1
,
6
a generator shaft which is installed in a center portion of the front bracket
2
and a center portion of the rear bracket
3
through a front bearing
7
and a rear bearing
8
so that it can turn,
9
a pulley which is fastened to the generator shaft
6
projecting forward from the front bracket
2
by a nut
10
so that it can turn together with the generator shaft
6
,
11
a cylindrical rotor which consists of a pair of a magnetic pole and a field core and is fitted onto the generator shaft
6
in the inside of the stator
5
so that it can turn together with the generator shaft
6
,
12
a front fan which is fixed to the front side of the magnetic pole of the rotor
11
,
13
a rear fan which is fixed to the rear side of the magnetic pole of the rotor
11
,
14
a plurality of slip rings which are spaced apart from one another in a direction parallel to the axial direction of the generator shaft
6
and are fixed to the generator shaft
6
between the rotor
11
and the rear bearing
8
by an unshown insulating member so that they can turn together with the generator shaft
6
,
15
a first resin part made from a synthetic resin and installed in the rear bracket
3
,
16
a cylindrical slinger portion made from a synthetic resin and provided at the center of the first resin part
15
to surround the slip rings
14
,
17
a brush holder portion made from a synthetic resin and provided in the first resin part
15
outside the slinger portion
16
,
18
a plurality of brushes corresponding to the number of slip rings
14
, which are inserted into the brush holder portion
17
and whose end portions projecting into the inside of the slinger portion
16
from the brush holder portion
17
are each contacted to the slip rings
14
,
19
a plurality of brush springs for pressing the plurality of brushes
18
against the slip rings
14
elastically, and
20
a voltage control function portion made from a synthetic resin and provided in the first resin part
15
at the rear of the brush holder
17
, to which a voltage regulator
21
is attached. Numeral
22
denotes a second resin part made from a synthetic resin and installed in the rear bracket
3
in such a manner that it does not interfere the first resin part
15
, and
23
a rectifying function portion made from a synthetic resin and provided in the second resin part
22
, to which a rectifier
24
comprising unidirectional conductive elements such as a diode is attached.
A description is subsequently given of the operation of the above car AC generator of the prior art when it is mounted on an automobile. The car AC generator is installed outside the cylinder block of an engine and a ring-shaped belt is stretched between a pulley provided on the crank shaft of the engine and the pulley
9
of the car AC generator. When a driver turns on the ignition switch of the automobile in this state, a current runs from the battery of the automobile to an ignition coil to start the engine and an excitation current runs into the brushes
18
, the slip rings
14
and the field coil of the rotor
11
from the battery through the voltage regulator
21
. When the generator shaft
6
turns by the start of the engine and then the rotor
11
turns in this state, three-phase AC induction electromotive force is generated in the coil of the stator
5
, rectified by the rectifier
24
and charged into the battery. The front fan
12
and the rear fan
13
turn by the rotation of the rotor
11
so that air in the engine room of the automobile is sucked into the inside space of the generator case
1
through suction holes in the front bracket
2
and suction holes in the rear bracket
3
. The intake air cools such parts as the stator
5
, the rotor
11
, the voltage regulator
21
and the rectifier
21
in the inside space of the generator case
1
and is then discharged into the engine room from exhaust holes in the front bracket
2
and exhaust holes in the rear bracket
3
.
In
FIG. 10
, the first resin part
15
of the capacitor has a capacitor mounting portion
25
made from a synthetic resin on one side of the slinger portion
16
in addition to the slinger portion
16
, the brush holder portion
17
and the voltage control function portion
20
. The capacitor mounting portion
25
has a hole
27
extending through a plate-like base portion
26
projecting sideways from the slinger portion
16
and the brush holder portion
17
and two resin side terminals
28
provided in the base portion
26
around the hole
27
in such a manner that they face each other. A capacitor container
29
is installed in the capacitor mounting portion
25
. As shown in
FIG. 11
, the capacitor container
29
contains a capacitor element
30
which is supported in the capacitor container
29
by a filling resin
31
such as an epoxy resin which is injected into a gap between the capacitor container
29
and the capacitor element
30
and solidified. The capacitor container
29
is inserted into the hole
27
, and two element side terminals
32
projecting outward from the capacitor container
29
are connected to the respective resin side terminal
28
by solder
33
. Therefore, the direction of injecting the filling resin
31
into the capacitor container
29
and the direction of connecting the element side terminals
32
to the respective resin side terminals
28
by the solder
33
are the same on the front side of the first resin part
15
, thereby improving assembly work efficiency. The capacitor element
30
is interposed between the positive pole and the negative pole of the generator so that it is connected to these electrodes in parallel and absorbs a surge generated by the voltage control of the voltage regulator
21
, thereby preventing the propagation of noise to car electric load devices such as an audio device and a blower fan.
Since the capacitor for a car AC generator of the prior art is constituted as described above, the capacitor container
29
separate from the first resin part
15
is inserted into the hole
27
of the first resin part
15
while the capacitor element
30
is fixed in the capacitor container
29
by the filling resin
31
, and the connection portions of the resin side terminals
28
and the element side terminals
32
bear the weight of the capacitor container
29
, the weight of the capacitor element
30
and the weight of the filling resin
31
. When the car AC generator is connected to the engine of the automobile, the engine of the automobile is driven, and vibration is transmitted from the engine to the car AC generator, the weight of the capacitor container
29
, the weight of the capacitor element
30
and the weight of the filling resin
31
serve as a vibration load on the connection portions of the resin side terminals
28
and the element side terminals
32
by the vibration repeatedly. Therefore, there is a possibility that these terminals are separated from each other. To cope with this, after the resin side terminals
28
are connected to the respective element side terminals
32
by the solder
33
, end portions of the resin side terminals
28
projecting from the element s

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