Inductor devices – Winding with terminals – taps – or coil conductor end...
Reexamination Certificate
2001-02-21
2003-01-28
Donovan, Lincoln (Department: 2832)
Inductor devices
Winding with terminals, taps, or coil conductor end...
C336S107000
Reexamination Certificate
active
06512440
ABSTRACT:
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an electromagnet assembly for use in an electromagnetic apparatus, such as an electromagnetic clutch for use in controlling the transmission of power from an automobile engine to a refrigerant compressor in an automobile air conditioning system. More particularly, it relates to a connector in the electromagnet assembly.
2. Description of Related Art
Referring to
FIG. 1
, an electromagnet assembly
7
, which comprises a ring member
1
, a coil bobbin
3
, and a ring case
4
, is known in the art. Ring member
1
has a toroidal shape having a spool portion, which has an exterior open edge formed by two anuular flanges on the spool portion. Coil bobbin
3
has ring member
1
and an electrical wire
2
, which is wound around the spool portion of ring member
1
. Ring case
4
has an annular groove, an open edge of which is in a direction parallel to its axis. Coil bobbin
3
is inserted into the annular groove of ring case
4
. An opening
4
a
is formed through ring case
4
adjacent to its closed end surface. A connector
5
is disposed on ring case
4
adjacent to its closed end surface and covers opening
4
a
. A first end
2
a
and a second end
2
b
of electrical wire
2
and a first lead
6
a
and a second lead
6
b
are joined, respectively in connector
5
. Electromagnet assembly
7
, for example, is used in an electromagnetic clutch
9
of a compressor
8
in an automobile air conditioning system, as shown in FIG.
2
. Electromagnet assembly
7
engages compressor
8
through a ring-shaped plate
10
, which is affixed to the closed end surface of ring case
4
.
Referring to
FIGS. 3-6
, the connecting structure between connector
5
and ring case
4
and the wiring connecting structure in connector
5
is shown. As shown in
FIGS. 3 and 4
, connector
5
has a case
5
a
having a box shape including a bottom and a cap
5
b
, which closes an open end of case
5
a
. Case
5
a
is fixed to ring case
4
by a pair of first hooks
10
a
formed on ring-shaped plate
10
which engage a pair of first receiving portions
5
a
1
formed on case
5
a
. Cap
5
b
is fixed to case
5
a
by engaging a plurality of second receiving portions
5
a
2
formed at case
5
a
with a plurality of hooks
5
b
1
formed at cap
5
b
. A projection portion
5
a
3
, which is formed on case
5
a
, is inserted into an opening
4
a
. An O-ring
11
, which is disposed in an annular groove formed on case
5
a
, surrounds opening
4
a
and abuts the closed end surface of ring case
4
.
As shown in
FIGS. 4-6
, first end
2
a
and second end
2
b
of electrical wire
2
are introduced into opening
4
a
through a notched portion
1
a
formed on a first end surface of ring member
1
and are extended into connector
5
through a pair of penetrating holes
5
a
4
, which are formed through projection portion
5
a
3
. A contact
12
having a first electric connection is connected to an end of second lead
6
b
, which is inserted into connector
5
. In addition, contact
12
having a second electric connection is connected to an end of first lead
6
a
, which is inserted into connector
5
. First end
2
a
of electrical wire
2
is supported between a first receiving portion formed at case
5
a
of connector
5
and a second receiving portion formed at contact
12
, which is connected to first lead
6
a
. Second end
2
b
of electrical wire
2
is supported between a third receiving portion formed at case
5
a
of connector
5
and a fourth receiving portion formed at contact
12
, which is connected to lead
6
b
. Thus, first end
2
a
and second end
2
b
of electrical wire
2
are connected to first lead
6
a
and second lead
6
b
, respectively.
Coil bobbin
3
is fixed to ring case
4
by a resin
13
(
e.g
., an epoxy resin), which is poured into an open end of the annular groove of ring case
4
. O-ring
11
, which is disposed between case
5
a
and the closed end surface of ring case
4
, prevents resin
13
from leaking to the outside of the closed end surface of ring case
4
through the gap between projection portion
5
a
3
of case
5
a
and a surrounding wall of opening
4
a
, when resin
13
is poured into ring case
4
.
In a known electromagnet assembly for use in an electromagnetic apparatus, it is necessary to engage the plurality of hooks
5
b
1
to the plurality of second receiving portions
5
a
2
when cap
5
b
of connector
5
is fixed to case
5
a
. Therefore, the manufacturing efficiency of fixing cap
5
b
to case
5
a
is low because this process is done by hand. Further, if the interior of case
5
a
does not fill with resin, water may enter into the interior of case
5
a
through the gap between cap
5
b
and case
5
a
, which is adjacent to an engagement portion of hook
5
b
1
and second receiving portion
5
a
2
, and the insulation capabilities of connecting portions of first end
2
a
and second end
2
b
of electrical wire
2
and contact
12
may be reduced. Therefore, it may be necessary to refill the interior of case
5
a
with resin
13
, and the manufacturing efficiency of fixing cap
5
b
to case
5
a
may be reduced.
SUMMARY OF THE INVENTION
An object of the present invention is to provide an electromagnet assembly for use in an electromagnetic apparatus which has a greater manufacturing efficiency in fixing a cap to a case of a connector, when compared with a known electromagnet assembly.
In an embodiment of the present invention, an electromagnet assembly for an electromagnetic apparatus comprises a ring member, a coil bobbin, a ring case, and a connector. The ring member comprises a tubular spool,
e.g.
, cylindrical spool, with a pair of annular flanges projecting radially from the spool. The coil bobbin comprises an electrical wire. The electrical wire is wound around the spool between the flanges. The ring case comprises an annular groove, which has an open edge. The coil bobbin is disposed in the ring case's annular groove. An opening is formed through the ring case adjacent to its closed end surface. The connector comprises a case and a cap. The case forms an enclosure, such as a cylinder or a box, having an open end and a bottom. The cap closes the open end of the case. The connector is disposed on the ring case adjacent to its closed end surface and covers the opening. A first end and a second end of the electrical wire, and a first lead wire and a second lead wire from an external electric circuit are connected to the first and the second ends, respectively in the connector. A projection portion is formed around a fringe portion of a first end surface of the cap and abuts an open end surface of the case. The cap is secured fixedly to the case after the projection portion is melted.
Other objects, features, and advantages will be apparent to persons of ordinary skill in the art from the following description of the invention with reference to the accompanying drawings.
REFERENCES:
patent: 5307038 (1994-04-01), Ishimaru
patent: 6091590 (2000-07-01), Sakamoto
patent: 3024894 (1982-01-01), None
patent: 19640261 (1998-04-01), None
patent: 0806583 (1997-11-01), None
patent: 7296896 (1995-11-01), None
Baker & Botts L.L.P.
Donovan Lincoln
Sanden Corporation
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