Electrical generator or motor structure – Dynamoelectric – Rotary
Reexamination Certificate
2002-11-04
2004-01-06
Lam, Thanh (Department: 2834)
Electrical generator or motor structure
Dynamoelectric
Rotary
C310S071000, C310S064000
Reexamination Certificate
active
06674193
ABSTRACT:
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an automotive alternator and, more particularly, to an assembly structure of a rectifying unit for an automotive alternator.
2. Description of the Related Art
FIG. 11
is a perspective view showing a conventional rectifying unit applied to an automotive alternator.
FIG. 12
is a sectional view of an essential section for explaining the conventional rectifying unit, which has been installed.
Referring to FIG.
11
and
FIG. 12
, a rectifying unit
120
includes a plurality of positive-electrode-side diodes
20
and negative-electrode-side diodes
21
for carrying out full-wave rectification on three-phase alternating current, a first cooling plate
122
and a second cooling plate
123
for cooling the positive-electrode-side diodes
20
and the negative-electrode-side diodes
21
, respectively, insulators
24
and
27
for insulating the first and second cooling plates
122
and
123
, a circuit board
125
, and an output terminal
26
. The positive-electrode-side diode
20
and the negative-electrode-side diode
21
constitute a first diode and a second diode, respectively.
The first cooling plate
122
is shaped like a horseshoe, and has the positive-electrode-side diodes
20
arranged on a main surface
122
a
thereof in the circumferential direction. A radiating fin
122
b
is vertically installed from the rear surface of the first cooling plate
122
, that is, the surface opposing the main surface. Three flanges
130
,
131
,
132
are provided at both ends and the middle, respectively, in the circumferential direction of the first cooling plate
122
. All the flanges
130
,
131
, and
132
are raised from a main surface
101
a
of the first cooling plate
101
, and extended outward in the radial direction. An output terminal insertion through hole
134
is provided in the radially extended end of the flange
130
provided at one circumferential end of the first cooling plate
122
. Mounting screw insertion through holes
133
are provided in the radially extended ends of the remaining flanges
131
and
132
.
The second cooling plate
123
, which is also shaped like a horseshoe, has a larger diameter than that of the first cooling plate
122
, and has the negative-electrode-side diodes
21
arranged on a main surface
123
a
thereof in the circumferential direction. Furthermore, one output terminal insertion through hole
138
, and two mounting screw insertion through holes
135
are provided at both ends and the middle in the circumferential direction of the second cooling plate
123
such that they align with the output terminal insertion through hole
134
and the mounting screw insertion through holes
133
provided in the first cooling plate
122
, respectively.
The circuit board
125
is a resinous molding having insert-molded wiring for constituting diode bridges for the positive-electrode-side diodes
20
and the negative-electrode-side diodes
21
, and horseshoe-shaped like the second cooling plate
123
. Furthermore, one output terminal insertion through hole
137
and two mounting screw insertion through holes
136
are provided at both ends and the middle in the circumferential direction of the circuit board
125
such that they align with the output terminal insertion through hole
134
and the mounting screw insertion through holes
133
provided in the first cooling plate
122
, respectively.
Each of the cylindrically shaped insulators
24
is made of, for example, a phenol resin, and has a flange
24
a
in the central portion of the outer periphery thereof. The cylindrically shaped insulator
27
is made of, for example, a phenol resin, and has a flange
27
a
at one end portion thereof. The output terminal
26
has a knurl groove portion
26
a
provided at the counter-takeout side and an external thread portion
26
b
provided at the takeout side.
The rectifying unit
120
is assembled as described below. First, the insulators
24
are inserted in the mounting screw insertion through holes
135
of the second cooling plate
123
such that the flanges
24
a
are in contact with the main surface
123
a
. Similarly, the insulator
27
is inserted in the output terminal insertion through hole
138
of the second cooling plate
123
such that the flange
27
a
is in contact with the main surface
123
a
. Then, the first cooling plate
122
is disposed such that the insulators
24
are inserted in the mounting screw insertion through holes
133
. This concentrically arranges the first and second cooling plates
122
and
123
, respectively, with their main surfaces
122
a
and
123
a
being flush with each other, and the positive-electrode-side diodes
20
and the negative-electrode-side diodes
21
facing each other. The circuit board
125
is stacked on the main surface
123
a
of the second cooling plate
123
such that the insulators
24
are inserted in the mounting screw insertion through holes
136
. Thus, connecting terminals
125
a
of the circuit board
125
are held between terminals
20
a
and
21
a
of the opposing positive-electrode-side and negative-electrode-side diodes
20
and
21
, respectively, and joined by soldering. Subsequently, the output terminal
26
is inserted from the output terminal insertion through hole
137
of the circuit board
125
into the output terminal insertion through holes
134
and
138
of the first and second cooling plates
122
and
123
, respectively. Lastly, the knurl groove portion
26
a
of the output terminal
26
is press-fitted into the output terminal insertion through hole
134
of the first cooling plate
122
to electrically connect the output terminal
26
and the first cooling plate
122
, completing the assembly of the rectifying unit
120
shown in FIG.
11
.
In the rectifying unit
120
assembled as described above, a mounting screw
40
inserted in the mounting screw insertion through holes
133
,
135
, and
136
is fastened into a tapped hole
2
a
provided in a rear bracket
2
so as to fasten together the first and second cooling plates
122
and
123
, and the circuit board
125
, as illustrated in FIG.
12
. The takeout end of the output terminal
26
connected to the first cooling plate
122
is extended out of an opening
2
b
provided in the rear bracket
2
. An output terminal fastening nut
50
threaded to the external thread portion
26
b
of the output terminal
26
is fastened thereby to fasten together an insulating bush
41
formed of a phenol resin mounted on the opening
2
b
of the bracket
2
, the first and second cooling plates
122
and
123
, and the circuit board
125
onto the rear bracket
2
.
To join a vehicular connecting terminal
42
to the output terminal
26
, the connecting terminal
42
is externally fitted to the takeout end of the output terminal
26
, and a nut
44
is screwed onto the external thread portion
26
b
. Then, the nut
44
is tightened to fasteningly secure the connecting terminal
42
to the outer end surface of the nut
50
. In this case the outer end surface of the output terminal fastening nut
50
serves as a fastening seat.
The first and second cooling plates
122
and
123
, the circuit board
125
, and the insulating bush
41
are secured together to the rear bracket
2
by the fastening force of the output terminal fastening nut
50
. With this arrangement, even if the vibration caused by a weight, such as a harness, is transmitted from the vehicle to the vehicular connecting terminal
42
, the output terminal
26
will not be displaced in the axial direction, thus initially preventing damage or the like to the rectifying unit
120
. Moreover, since the fastening force of the nut
44
is received by the outer end surface of the output terminal fastening nut
50
making up the fastening seat, the fastening force for the vehicular connecting terminal
42
is initially secured.
In the conventional automotive alternator, since the rectifying unit
120
is assembled and installed as set forth above, when power is generated by the automotive alternator, la
Lam Thanh
Mitsubishi Denki & Kabushiki Kaisha
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