Electrical generator or motor structure – Dynamoelectric – Rotary
Reexamination Certificate
1999-06-23
2001-08-07
Ramirez, Nestor (Department: 2834)
Electrical generator or motor structure
Dynamoelectric
Rotary
C363S144000, C363S145000
Reexamination Certificate
active
06271607
ABSTRACT:
FIELD OF THE INVENTION
This invention relates to sub-assemblies for motor vehicle alternators, the sub-assemblies being of the kind (such as brush carriers or connectors) which include electronic components.
BACKGROUND OF THE INVENTION
In a motor vehicle alternator, it is typical practice at the present time to arrange the brush carrier or connector in the form of a substrate together with an integrated circuit component, or chip, which is mounted in a through hole formed in the substrate. Such an arrangement is sometimes called naked chip assembly. When the sub-assembly also includes an elementary electronic component such as an inductor, a capacitor, a resistor or a diode, a component is provided which extends through the substrate and which is secured by brazing or electrical soldering on the conductive strips which are associated with the chip. However, this arrangement gives rise to the need for a specific mounting and soldering operation. This means that manufacture is lengthy and costly. In addition, it is necessary to provide specific connections on the components of the sub-assembly, and to protect the soldered connections against corrosion and short circuits.
DISCUSSION OF THE INVENTION
An object of the invention is to provide a sub-assembly which is quicker and cheaper to make.
According to the invention in a first aspect, a regulator sub-assembly for an alternator, comprising a substrate having an aperture, an integrated circuit component mounted in the aperture, and an elementary electronic component other than an integrated circuit, the said elementary component being fixed to the substrate, is characterised in that the elementary component is surface mounted on the substrate.
Thus in a sub-assembly according to the invention, it is possible to deposit the elementary component on the substrate at the same time as the integrated circuit component is placed in position. In consequence, these two placings can be carried out one after the other by the same machine. It is then no longer necessary to provide a specific positioning step for the elementary component. In this way manufacture is made faster, and the cost price of the sub-assembly is reduced. In addition, the material for attachment to the substrate, for example by adhesive bonding or brazing, can be the same material for both of the two electronic components, and this again gives rise to economy.
The substrate is preferably formed with a recess contiguous to the aperture, the elementary component being mounted in the recess.
Preferably, the integrated circuit component and the elementary electronic component are both encapsulated within a common uninterrupted layer of a suitable protective material. Thus protection of both of these components can be ensured in a common single step of the manufacturing process.
The sub-assembly preferably includes a protective cover overlying the integrated circuit component and the elementary electronic component. This provision of a protective cover, common to both of the electronic components, reduces the amount of material that has to be used, and also the number of steps in the manufacturing process.
The elementary electronic component is preferably connected directly to one terminal of the integrated circuit component.
The elementary component may consist of a capacitor, and is preferably connected directly to the ground of the sub-assembly.
The sub-assembly may include means for mounting carbon brushes in the alternator; alternatively it may for example include a connector.
According to the invention in a second aspect, an alternator, in particular for a motor vehicle, includes a sub-assembly according to the first aspect of the invention.
According to the invention in a third aspect, a method of making a regulator sub-assembly for an alternator, in which an integrated circuit component is mounted within a through aperture in a substrate of the sub-assembly, and an elementary electronic component other than an integrated circuit is fixed to the substrate, is characterised in that the elementary component is surface mounted on the substrate.
Further features and advantages of the invention will appear more clearly on a reading of the following detailed description of a preferred embodiment of the invention, which is given by way of non-limiting example only and with reference to the accompanying drawing.
REFERENCES:
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patent: 4992688 (1991-02-01), Cap et al.
patent: 5248910 (1993-09-01), Yockey et al.
patent: 5386343 (1995-01-01), Pao
patent: 5677616 (1997-10-01), Ooiwa
patent: 5747875 (1998-05-01), Oshima
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patent: 5838544 (1998-11-01), Wei
patent: 0 258 691 (1987-08-01), None
French Search Report dated Feb. 12, 1999.
Dinh Le Dang
Morgan & Finnegan , LLP
Ramirez Nestor
Valeo Equipments Electriques Moteur
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