Electrical generator or motor structure – Dynamoelectric – Rotary
Reexamination Certificate
2001-04-20
2003-03-25
Dougherty, Thomas M. (Department: 2834)
Electrical generator or motor structure
Dynamoelectric
Rotary
C310S071000, C310S06800R, C310S058000, C310S064000
Reexamination Certificate
active
06538352
ABSTRACT:
This application is based on Application No. 2000-340220, filed in Japan on Nov. 8, 2000, the contents of which are hereby incorporated by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an automotive alternator.
2. Description of the Related Art
FIG. 17
is a cross section showing a construction of a conventional automotive alternator,
FIG. 18
is a rear end elevation of the conventional automotive alternator,
FIG. 19
is a perspective showing a rotor used in the conventional automotive alternator, and
FIG. 20
is a perspective showing a stator used in the conventional automotive alternator.
In
FIGS. 17
to
20
, the conventional automotive alternator is constructed by rotatably mounting a Lundell-type rotor
7
by means of a shaft
6
inside a case
3
constructed from an aluminum front bracket
1
and an aluminum rear bracket
2
, and fixing a stator
8
to an inner wall surface of the case
3
so as to cover an outer circumferential side of the rotor
7
.
The shaft
6
is rotatably supported in the front bracket
1
and the rear bracket
2
. A pulley
4
is fastened to a first end of this shaft
6
such that rotational torque from an engine can be transmitted to the shaft
6
by means of a belt (not shown).
Slip rings
9
for supplying electric current to the rotor
7
are fixed to a second end of the shaft
6
, and a pair of brushes
10
are housed in a brush holder
11
disposed inside the case
3
such that the pair of brushes
10
slide in contact with the slip rings
9
. A voltage regulator
18
for adjusting the magnitude of an alternating voltage generated in the stator
8
is fixed by adhesive to a regulator heat sink
17
fitted onto the brush holder
11
. A rectifier
12
that is electrically connected to the stator
8
and converts alternating current generated in the stator
8
into direct current is mounted inside the case
3
.
The rotor
7
is constituted by a rotor coil
13
for generating magnetic flux on passage of an electric current, and a pair of first and second pole cores
20
and
21
disposed so as to cover the rotor coil
13
, magnetic poles being formed in the first and second pole cores
20
and
21
by magnetic flux generated in the rotor coil
13
. The pair of first and second pole cores
20
and
21
are made of iron, each has a plurality of first and second claw-shaped magnetic poles
22
and
23
disposed on an outer circumferential perimeter at even pitch in a circumferential direction so as to project axially, and the first and second pole cores
20
and
21
are fixed to the shaft
6
facing each other such that the first and second claw-shaped magnetic poles
22
and
23
intermesh. In addition, centrifugal fans
5
are fixed to first and second axial ends of the rotor
7
.
The stator
8
is constituted by a stator core
15
, and a stator winding
16
formed by winding a conducting wire into this stator core
15
, electric current being generated in the stator winding
16
by changes in the magnetic flux from the rotor
7
accompanying rotation of the rotor
7
. The stator core
15
is formed into a cylindrical shape, and a plurality of slots
15
a
having grooves lying parallel to an axial direction are disposed at even angular pitch in a circumferential direction so as to open towards an inner circumferential side. The stator winding
16
is formed into a generally cylindrical shape by winding and stacking copper wires (conductor wires) having a circular cross section coated with electrical insulation into a wave shape, and is mounted to the stator core
15
by inserting the copper wires into each of the slots
15
a
from axially outside while bending a first coil end portion thereof towards an inner circumferential side.
Next, the construction of the rectifier
12
and the voltage regulator
18
will be explained with reference to
FIGS. 22
to
28
.
The brush holder
11
is made of an electrically-insulating resin, and is formed integrally with an annular shaft insertion portion
30
, a circuit housing portion
31
, a connector portion
32
, and a mounting portion
33
. An insert conductor group is insert molded into the brush holder
11
, constituting wiring for component parts, also constituting connection terminals protruding out into the connector portion
32
, and further constituting rectifier connection terminals
34
, etc., functioning as electrical joint portions for the rectifier
12
. The voltage regulator
18
is constructed by securing a voltage regulator circuit board (not shown) mounted with electronic components such as IC chips onto the regulator heat sink
17
using adhesive. The voltage regulator
18
is mounted in the circuit housing portion
31
by fitting the regulator heat sink
17
into the circuit housing portion
31
and sealing edge portions of the regulator heat sink
17
to the circuit housing portion
31
. The voltage regulator circuit board of the voltage regulator
18
is housed inside the circuit housing portion
31
and sealed in using a resin. Brush holder mounting apertures
33
a
are disposed at first and second ends of the mounting portion
33
.
The rectifier
12
is constituted by horseshoe-shaped first and second heat sinks
37
and
38
upon which are disposed first and second unidirectional conducting component packages
35
and
36
, respectively, and a horseshoe-shaped rectifier circuit board
39
. Each of the first unidirectional conducting component packages
35
is formed into a generally rectangular parallelepiped shape by molding a first diode
35
a
using a first electrically-insulating resin portion
35
d,
each of the first diodes
35
a
functioning as a semiconductor component constructed by joining an n-type semiconductor and a p-type semiconductor into a pn junction, a first heat-dissipating copper tab
35
b
being joined to the n-type semiconductor and a first diode connection terminal
35
c
being joined to the p-type semiconductor. Each of the second unidirectional conducting component packages
36
is formed into a generally rectangular parallelepiped shape by molding a second diode
36
a
using a second electrically-insulating resin portion
36
d,
each of the second diodes
36
a
functioning as a semiconductor component constructed by joining an n-type semiconductor and a p-type semiconductor into a pn junction, a second heat-dissipating copper tab
36
b
being joined to the p-type semiconductor and a second diode connection terminal
36
c
being joined to the n-type semiconductor. Eight first unidirectional conducting component packages
35
are arranged in a circumferential direction with the first heat-dissipating copper tabs
35
b
joined to a main surface of the first heat sink
37
, and a plurality of heat-dissipating fins
37
a
are disposed in a radial pattern on a rear surface of the first heat sink
37
. Similarly, eight second unidirectional conducting component packages
36
are arranged in a circumferential direction with the second heat-dissipating copper tabs
36
b
joined to a main surface of the second heat sink
38
. In the rectifier circuit board
39
, an insert conductor group is formed by insert molding and constitutes first rectifier circuit board connection terminals
39
b
functioning as electrical joint portions for the first and second diode connection terminals
35
c
and
36
c
of the first and second unidirectional conducting component packages
35
and
36
and second rectifier circuit board connection terminals
39
c
functioning as electrical joint portions for the voltage regulator
18
. In addition, rectifier circuit board mounting apertures
39
a
are disposed at first and second end portions and a central portion of the rectifier circuit board
39
. Moreover, one of the rectifier circuit board mounting apertures
39
a
is used as an output terminal for the rectifier
12
.
The rectifier
12
is constructed by disposing the first and second rectifier heat sinks
37
and
38
coaxially such that main surfaces thereof are positioned in a common plane, disposing the rectifier circuit board
Dougherty Thomas M.
Gonzalez Julio C.
Mitsubishi Denki & Kabushiki Kaisha
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