Alternator bearing sleeve, brush holder, and cap system

Details Alternator bearing sleeve, brush holder, and cap system Alternator bearing sleeve, brush holder, and cap system

1999-05-10

2001-04-10

Ramirez, Nestor (Department: 2834)

Electrical generator or motor structure

Dynamoelectric

Rotary

C310S088000, C310S239000

Reexamination Certificate

active

06215211

ABSTRACT:

BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to rotating electric machines, and more specifically to a system for mounting brushes on an automotive vehicle alternator which comprises an assembly of a bearing sleeve, the brush holder, and a cap.
2. Background Information
A known automotive vehicle electrical system comprises a D.C. storage battery that is kept charged by an alternator that is powered by the vehicle's engine. Like similar rotating electric machines, a known automotive vehicle alternator contains electrically conductive brushes that are disposed in a brush holder mounted on a non-rotating portion of the electric machine and are spring-biased against conductive rings on a rotating portion of the machine for conveying electric current between rotating and non-rotating elements.
A known technique for mounting a brush holder on an alternator comprises joining the brush holder and a second piece together, such as by molding the second piece onto the brush holder for example, and then attaching the assembled pieces to the alternator housing, for example by fastening the second piece to the rear of the alternator housing by threaded fasteners. An example of this technique is represented by a Ford model 3G brush holder assembly.
Another known technique comprises integrating the brush holder with a rear bearing sleeve of the alternator. An example of this technique appears in U.S. Pat. No. 5,296,772.
It is believed to important for a brush holder to be rigidly mounted on an alternator in order to avoid potentially detrimental effects from repeated vibration to which the alternator is subjected during use on an automotive vehicle engine.
U.S. Pat. Nos. 3,233,130; 3,963,949; 4,680,495; 4,959,576; and 5,345,132; are believed representative of the state of the art. They disclose various forms of brush holder mountings.
SUMMARY OF THE INVENTION
One general aspect of the invention relates to an assembly for use with a rotating electric machine having an element which rotates about a longitudinal axis of the machine and with which the assembly co-axially associates, the assembly comprising: a first non-metallic part and a second non-metallic part mutually assembled; the second part comprising a brush guide containing a brush for establishing electric contact with a rotating element of the machine; each part comprising a respective pair of channels each of which has a length parallel to the longitudinal axis and respectively mutually interlocks with a respective one of the pair of channels of the other part; each interlocking pair of channels comprising a respective surface on the first part that is disposed in a plane parallel to the longitudinal axis and is mutually abutting a respective surface on the second part that is also disposed in a plane parallel to the longitudinal axis; each interlocking pair of channels further comprising a respective wedging surface that runs lengthwise along the respective channel of one of the parts and wedges a respective wedged surface that runs lengthwise along the respective channel of the other part to cause the mutually abutting surfaces of each respective pair of channels to forcefully mutually abut.
Another general aspect relates to an assembly for use with a rotating electric machine having an element which rotates about a longitudinal axis of the machine and with which the assembly co-axially associates, the assembly comprising: a first non-metallic part, a second non-metallic part, and a third non-metallic part; the first part and the second part comprising two pairs of mutually interlocking channels that associate the first part and the second part in mutual assembly; the first part comprising an open area across which channels of the first part confront each other, a transverse wall with which lengthwise ends of the channels of the first part join and away from which the channels of the first part extend in one direction along the longitudinal axis, a partially cylindrical shroud that is disposed about the longitudinal axis and at one axial end, joins with the transverse wall, and along the one direction of the longitudinal axis, joins with the channels of the first part, a cylindrical wall extending from the transverse wall in the other direction along the longitudinal axis to form a bearing cup for receiving a bearing assembly for journaling the machine element, and a through-hole in the transverse wall concentric with the longitudinal axis for providing through-passage of the machine element; the second part comprising two side-by-side brush guides each containing a respective brush for establishing electric contact with respective conductors on the machine element; and a third part comprising a closure that closes an axial end of the shroud opposite the axial end of the shroud that joins with the transverse wall and an attachment that attaches the third part to the second part.
Another general aspect relates to an assembly for use with a rotating electric machine having an element which rotates about a longitudinal axis of the machine and with which the assembly co-axially associates, the assembly comprising: a first injection-molded plastic part and a second injection-molded plastic part mutually assembled; the second part comprising a brush guide containing a brush for establishing electric contact with the machine element; each part comprising a respective pair of channels each of which has a length parallel to the longitudinal axis and respectively mutually interlocks with a respective one of the pair of channels of the other part; each pair of mutually interlocking channels comprising a respective surface on the first part that is disposed in a plane parallel to the longitudinal axis and in mutual abutment with a respective surface on the second part that is also disposed in a plane parallel to the longitudinal axis; each interlocking pair of channels further comprising a respective wedging surface that runs lengthwise along the respective channel of one of the parts and wedges a respective wedged surface that runs lengthwise along the respective channel of the other part to cause the mutually abutting surfaces of each respective pair of channels to forcefully mutually abut.
Another general aspect relates to a method of making an assembly for use with a rotating electric machine having an element which rotates about a longitudinal axis of the machine and with which the assembly co-axially associates, the method comprising: fabricating a first part by injection-molding plastic in a mold cavity having a single axis of draw that is along the longitudinal axis, including molding a pair of lengthwise extending channels each of which has a respective zero draft surface and a respective non-zero-draft wedging surface; fabricating a second part by injection-molding plastic in a mold cavity having a single axis of draw that is along the longitudinal axis, including molding a pair of lengthwise extending channels for interlocking with the channels of the first part, including molding each channel of the second part to have a respective zero draft surface and a respective non-zero-draft wedged surface, and including molding a brush guide for an electric brush; assembling the first and second parts together by aligning the channels of the first part with those of the second part and relatively moving the first and second parts along the longitudinal axis to mutually interlock each channel of the first part with a respective channel of the second part, including causing each wedging surface to act on a respective wedged surface so as to cause the zero draft surfaces of the respective pair of mutually interlocking channels to forcefully mutually abut.
Another general aspect relates to a method of making an assembly for use with a rotating electric machine having an element which rotates about a longitudinal axis of the machine and with which the assembly co-axially associates, the method comprising: fabricating a first part by injection-molding plastic, including molding a pair of lengthwise

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