Inductor devices – Winding formed of plural coils – Coil supports or spacers
Reexamination Certificate
2002-10-30
2004-03-16
Mai, Anh (Department: 2832)
Inductor devices
Winding formed of plural coils
Coil supports or spacers
C336S221000, C336S205000, C439S164000
Reexamination Certificate
active
06707365
ABSTRACT:
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an electromagnetic coupling 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 connection to a connector in the electromagnetic coupling apparatus.
2. Description of Related Art
In
FIG. 1
, a known compressor
110
of an automobile air conditioning system is shown. Compressor
110
may include an electromagnetic clutch
109
. Electromagnetic clutch
109
may selectively connect and disconnect a drive source to a drive shaft of compressor
110
.
Electromagnetic clutch
109
may include an electromagnetic coupling apparatus A. An electromagnetic coupling apparatus A comprises an annular ring case
104
, a coil assembly
100
, and a connector
103
(shown in FIGS.
2
and
3
). Coil assembly
100
is disposed in an annular groove
104
b
of ring case
104
. A bottom portion of ring case
104
is fixed to a housing of compressor
110
, via a plate
105
.
As shown in
FIG. 2
, coil assembly
100
includes a coil bobbin
102
and a coil
101
wound around coil bobbin
102
. Coil
101
comprises of an electrical wire. Coil
101
has end portions
101
a
,
110
b
. An opening
104
a
is formed through a bottom portion of ring case
104
. Coil assembly
100
may be positioned within annular groove
104
b
of ring case
104
, so that end portions
101
a
,
101
b
of coil
101
pass through opening
104
a
. After passing through opening
104
a
, end portions
101
a
,
101
b
of coil
101
may be secured in connector
103
. Within connector
103
, each of end portions
101
a
,
101
b
of coil
101
may be connected electrically with a respective one of a pair of external wires
106
a
,
106
b
. Connector
103
may be secured to ring case
104
, so that a portion of connector
103
fits into opening
104
a
of ring case
104
.
With reference to
FIG. 3
, connector
103
includes a hook receiving portions
103
a
,
103
b
. By grasping looks
105
a
,
105
b
of plate
105
into hook receiving portions
103
a
,
103
b
of connector
103
, connector
103
may be fixed to the bottom portion of ring case
104
.
In the known electromagnetic coupling apparatus A, the plurality of hooks
105
a
,
105
b
must engage the plurality of hook receiving portions
103
a
,
103
b
by hand. Therefore, the manufacturing efficiency connecting connector
103
to ring case
104
is reduced. If hooks
105
a
,
105
b
are engaged to hook portions
103
a
,
103
b
, the grasping tool may damage connector
103
. Further, in the known electromagnetic coupling apparatus A, the plurality of hooks
105
a
,
105
b
are formed in the plate
105
, which increases the size of plate
105
.
SUMMARY OF THE INVENTION
Therefore, a need has arisen for electromagnetic coupling apparatus for use in an electromagnetic clutch that overcome these and other shortcomings of the related art. A technical advantage of the present invention is that grasping portions are not required to connect a connector to a ring case.
In an embodiment of this invention, an electromagnetic coupling apparatus comprises a ring case, a coil and a connector. The ring case comprises an annular groove, which has an open edge. The coil comprises an electrical wire and is disposed in the annular groove of the ring case. An opening is formed through the ring case in its closed end surface. The connector is disposed on the closed end surface of the ring case and covers the opening. Each of a first end and a second end of the coil are connected to one of a pair of lead wires, respectively, of an electric circuit via one of a pair of contacts, respectively in the connector. The connector comprises a housing and a cap. The housing supports the first and the second ends of the coil and the pair of contacts in its interior. The cap closes an end opening of the housing. The coil is covered substantially by an annular resin case. The housing is formed integrally with the annular resin case.
In another embodiment of this invention, an electromagnetic coupling apparatus comprises a ring case, a coil and a connector. The ring case comprises an annular groove, which has an open edge. The coil comprises an electrical wire and is disposed in the annular groove of the ring case. An opening is formed through the ring case in its closed end surface. The connector is disposed on the closed end surface of the ring case and covers the opening. Each of a first end and a second end of the coil are connected to one of a pair of lead wires, respectively, of an electric circuit via one of a pair of contacts, respectively in the connector. The connector comprises a housing and a cap. The housing supports the first and the second ends of the coil and the pair of contacts in its interior. The cap closes an end opening of the housing. A resin annularly encases the entire the coil. The housing is formed integrally with the annular resin mold.
In still another embodiment of this invention, an electromagnetic coupling apparatus comprises a ring case, a coil and a connector. The ring case comprises an annular groove, which has an open edge. The coil comprises an electrical wire and is disposed in the annular groove of the ring case. An opening is formed through the ring case in its closed end surface. The connector is disposed on the closed end surface of the ring case and covers the opening. Each of a first end and a second end of the coil are connected to one of a pair of lead wires, respectively, of an electric circuit via one of a pair of contacts, respectively in the connector. The connector comprises a housing and a cap. The housing supports the first and the second ends of the coil and the pair of contacts in its interior. The cap closes an end opening of the housing. The coil is covered substantially by an annular resin case. The housing is glued on an end surface of the annular resin case that is disposed to correspond to the opening of the ring case.
In yet another embodiment of this invention, an electromagnetic coupling apparatus comprises a ring case, a coil and a connector. The ring case comprises an annular groove, which has an open edge. The coil comprises an electrical wire and is disposed in the annular groove of the ring case. An opening is formed through the ring case in its closed end surface. The connector is disposed on the closed end surface of the ring case and covers the opening. Each of a first end and a second end of the coil are connected to one of a pair of lead wires, respectively, of an electric circuit via one of a pair of contacts, respectively in the connector. The connector comprises a housing and a cap. The housing supports the first and the second ends of the coil and the pair of contacts in its interior. The cap closes an end opening of the housing. A resin annularly encases the entire the coil. The housing is glued on an end surface of the annular resin case that is disposed to correspond to the opening of the ring case.
In a further embodiment, the invention comprises a method for assembling an electromagnetic coupling apparatus. The method comprises the steps of: encasing a coil covered substantially by an annular resin encasement, e.g., an annular resin case or an annular resin mold, in a ring case, and positioning a housing of a connector, which is formed integrally with the annular resin encasement, in an opening of the ring case. This method further comprises the steps of connecting a plurality of contacts with a pair of lead wires and with a plurality of support portions of the housing; and closing an end opening of the housing by a cap of the connector. In this method, the encasing step and the positioning step may be performed simultaneously.
Other objects, features, and advantages of embodiments of this invention will be apparent to, and understood by, persons of ordinary skill in the art from the following description of preferred embodiments with reference to the accompanying drawings.
R
Baker & Botts L.L.P.
Mai Anh
Sanden Corporation
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