AU2019201082B2

AU2019201082B2 - Insulated output assembly for vehicle alternating current generator

Info

Publication number: AU2019201082B2
Application number: AU2019201082A
Authority: AU
Inventors: Hung-Chih Chang; Muditha Upul Bandara Etipola; Fu-sheng LIANG; I-Wen Annie Yao
Original assignee: Victory Industrial Corp
Current assignee: Victory Industrial Corp
Priority date: 2019-02-15
Filing date: 2019-02-15
Publication date: 2020-09-17
Anticipated expiration: 2039-02-15
Also published as: TWI699944B; AU2019201082A1; TW202032898A

Abstract

The present disclosure provides an insulated output assembly for a vehicle alternating current (AC) generator including a rectifier, and an insulated terminal structure. The rectifier includes an arc-shaped conducting plate that has two legs each having a terminal. 5 The insulated terminal structure is selectively coupled to any one of the terminals in either of two different directions. 1/12 121 1 3F 5a 5 22, 5b FIG. 1

Description

1/12

121 1

3F

a 5

22,

5b

FIG. 1

INSULATED OUTPUT ASSEMBLY FOR VEHICLE ALTERNATING CURRENT GENERATOR

Technical Field

[0001] The present disclosure generally relates to an insulated output assembly, and more

particularly to an insulated output assembly for a vehicle alternating current (AC) generator.

Background

[0002] An alternating-current generator is used for converting mechanical energy into

alternating-current electric energy. In a vehicle altemating-current generator, the output power

of an engine drives a rotor of the generator to rotate within a stator to convert mechanical

energy of the engine into electric energy to charge a storage battery, which then supplies

electric energy to electrical parts of a vehicle.

[0003] A vehicle alternating-current generator typically has an annular stator and a rotor.

By means of rapid rotation of the rotor in the annular stator, magnetic fields are formed by

wires wound around the annular stator so as to generate an induced electromotive force

(voltage) in the wires and an inductive current. In general, the generated current is an AC,

which periodically reverses direction. In order to provide a direct current (DC) that flows in

only one direction to a battery and some other components of a vehicle, a rectifier is required

to convert the AC to DC. Furthermore, a vehicle AC generator contains a terminal structure

coupled to the rectifier for transmitting DC to one or more electronic components of the

!0 vehicle. Because there are many types of vehicle on the market, the location and orientation

of each terminal structure varies in order to conform to the corresponding type of vehicle.

Thus, manufacturers have no choice but to design and manufacture many types of insulated

output assemblies for AC generators to conform to the corresponding vehicle, resulting in

higher costs.

Lee and Li Attorneys-at-Law Docket No: V33688/AU7932

[00041 Given the above, what is needed is an insulated output assembly for a vehicle

alternating current (AC) generator that is applicable to different types of vehicle.

[0004a] In the claims and description of the invention, except where the context requires

otherwise due to express language or necessary implication, the word "comprise" or variations

such as "comprises" or "comprising" is used in an inclusive sense, i.e. to specify the presence

of the stated features but not to preclude the presence or addition of further features in various

embodiments of the invention.

[0004b] It is to be understood that, if any prior art publication is referred to herein, such reference does not constitute an admission that the publication forms a part of the common general knowledge in the art, in Australia or any other country.

Summary of Invention

[0005] In accordance with the present invention, there is provided an insulated output

assembly for a vehicle alternating current (AC) generator, comprising: a rectifier, comprising:

an arc-shaped positive plate having a first leg and a second leg each having a terminal; a

regulator extending under the second leg; and an insulated terminal structure selectively

coupled to any one of the terminals in either of two different directions.

Brief Description of the Drawings

!0 [0006] The invention as well as a preferred mode ofuse, further objectives, and advantages

thereof will be best understood by referring to the following detailed description of illustrative

embodiments in conjunction with the accompanying drawings, wherein:

[00071 FIG. 1 is a perspective view of an insulated output assembly for a vehicle AC

generator according to a first embodiment of the present disclosure;

!5 [0008] FIG. 2 is an exploded view of the insulated output assembly in FIG. 1;

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Lee and Li Attorneys-at-Law Docket No: V33688/AU7932

[0009] FIG. 3 is a perspective view of the insulated output assembly in FIG. 1 with the

housing omitted;

[0010] FIG. 4 is a perspective view of a rectifier of the insulated output assembly in FIG.

3;

[0011] FIG. 5 is a bottom view of the rectifier in FIG. 4;

[0012] FIG. 6 is a perspective view of a base of an arc-shaped positive plate of a rectifier

in FIG. 4;

[continued on page 3]

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[00131 FIG. 7A is a front view of the an insulated terminal structure in FIG. 1;

[0014] FIG. 7B is a cross-sectional view of the insulated terminal structure in FIG. 7A;

[0015] FIG. 8 is a perspective view of an insulated output assembly for a vehicle AC

generator according to a second embodiment of the present disclosure;

[0016] FIG. 9 is an exploded view of the insulated output assembly in FIG. 8;

[00171 FIG. 1OA is a front view of the an insulated terminal structure in FIG. 8;

[00181 FIG. 1OB is a cross-sectional view of the insulated terminal structure in FIG.1OA;

[0019] FIG. 11 is a perspective view of an insulated output assembly for a vehicle AC

generator according to a third embodiment of the present disclosure;

[0020] FIG. 12 is an exploded view of the insulated output assembly in FIG. 11;

[0021] FIG. 13 is a perspective view of an insulated output assembly for a vehicle AC

generator according to a fourth embodiment of the present disclosure; and

[0022] FIG. 14 is an exploded view of the insulated output assembly in FIG. 13.

Detailed Description

[0023] The characteristics, subject matter, advantages, and effects of the present

disclosure are detailed hereinafter by reference to embodiments of the present disclosure and

the accompanying drawings. It is understood that the drawings referred to in the following

description are intended only for purposes of illustration and do not necessarily show the

actual proportion and precise arrangement of the embodiments. Therefore, the proportion

!0 and arrangement shown in the drawings should not be construed as limiting or restricting the

scope of the present invention.

[00241 The terminology used in the description of the present disclosure herein is for the

purpose of describing particular embodiments only and is not intended to be limiting of the

invention. As used in the description of the invention and the appended claims, the singular

forms "a," "an" and "the" are intended to include the plural forms as well, unless the context

clearly indicates otherwise. It will also be understood that the term "and/or" as used herein

refers to and encompasses any and all possible combinations of one or more of the associated

listed items. It will be further understood that the terms "includes," "including," "comprises,"

and/or "comprising," when used in this specification, specify the presence of stated features,

integers, steps, operations, elements, and/or components, but do not preclude the presence or

addition of one or more other features, integers, steps, operations, elements, components,

and/or groups thereof.

[0025] FIG. 1 is a perspective view of an insulated output assembly 1 for a vehicle AC

generator according to a first embodiment of the present disclosure, FIG. 2 is an exploded

view of the insulated output assembly 1 in FIG. 1, and FIG. 3 is a perspective view of the

insulated output assembly 1 in FIG. 1 wherein the housing 2 is omitted. Referring to FIGS.

1-3, a vehicle alternating current (AC) generator includes an insulated output assembly 1.

The insulated output assembly 1 is coupled to a stator and rotor assembly (not shown) that is

configured to convert mechanical energy into electrical energy in the form of AC. The

insulated output assembly 1 includes a housing 2, a rectifier 3, and at least one insulated

!0 terminal structure 4. The housing 2 accommodates the rectifier 3, and has a top side 21 and

a lateral side 22 connected to the circumference of the top side 21. The housing 2 also

defines a first aperture 5, a second aperture 5a, and a third aperture 5b. Each of the first

aperture 5 and the second aperture 5a is formed on both the top side 21 and the lateral side 22

of the housing 2. The third aperture 5b as shown in Fig. 1 is formed on the lateral side 22 while in other embodiments, it may be formed on the top side 21. The third aperture 5b in one embodiment is located between the first aperture 5 and the second aperture 5a.

[0026] As shown in FIG. 2, in this embodiment, the housing 2 has rims 24 surrounding

the two apertures 50, 50a respectively. The rim 24 which defines the first aperture 5 has an

upper portion 50a and a lower portion 50b. The upper portion 50a is generally perpendicular

to the lower portion 50b. The upper portion 50a has a first section 51, a second section 52, a

third section 53 and a fourth section 54 that are connected in series. The first section 51 is

semicircular in shape. The second section 52, the third section 53 and the fourth section 54

are rectangular in shape. The width of the second section 52 is greater than that of the fourth

section 54 and less than that of the third section 53. Also, the diameter of the first section 51

is equal to the width of the second section 52. The housing 2 has two blocks 23 that define

the fourth section 54. Moreover, the lower portion 50b has a fifth section 55 and a sixth

section 56. The fifth section 55 is rectangular in shape, and the sixth section 56 is

semicircular in shape and communicates with the fifth section 55. The width of the fifth

section 55 and the diameter of the sixth section 56 are equal to the width of the fourth section

54. The configuration of the second aperture 5a is substantially the same as that of the first

aperture 5, and therefore is not repeatedly described herein for the sake of brevity.

[00271 FIG. 4 is a perspective view of the rectifier 3 of the insulated output assembly 1

shown in FIG. 3. In FIG. 4, the regulator 9 and the air-guiding plate 30 shown in Fig. 3 are

!0 omitted. Referring to FIGS. 3 and 4, the rectifier 3 includes an arc-shaped positive plate 6, a

negative plate 7, a conduction plate 8, a regulator 9 and an air-guiding plate 30. The

air-guiding plate 30 is generally disk-shaped with a central hole 32 therein. The arc-shaped

positive plate 6, the negative plate 7, the conduction plate 8 and the regulator 9 are disposed

on the air-guiding plate 30. The conduction plate 8 is sandwiched between the negative

!5 plate 7 and the arc-shaped positive plate 6. Furthermore, the rectifier 3 of the insulated output assembly 1 is defined to have a first half portion 12 and a second half portion 14 defined by a virtual line L as shown in Fig. 3. Each of the first half portion 12 and the second half portion 14 is generally in a semi-circular shape. The arc-shaped positive plate 6, the negative plate 7 and the conduction plate 8 are mainly located within the first half portion

12, whereas the regulator 9 is mainly located within the second half portion 14.

[00281 FIG. 5 is a bottom view of the rectifier 3 in FIG. 4. Referring to FIGS. 4-5, in

one embodiment, the conduction plate 8 includes a generally U-shaped body that is made of

plastic. The conduction plate 8 is coupled to the arc-shaped positive plate 6 and the negative

plate 7 with its upper and lower sides. The conduction plate 8 has multiple mounting holes

80 therein, multiple contacts 82 and multiple pins 84 thereon. Multiple fixing members 86,

for example, screws, are disposed in the mounting holes 80 for securing the arc-shaped

positive plate 6 and the negative plate 7 to the conduction plate 8. The contacts 82 are

disposed on the outer periphery of the conduction plate 8. The stator and rotor assembly

(not shown) are coupled to the rectifier 3 via the contacts 82 for transmitting AC to the

rectifier 3.

[0029] FIG. 6 is a perspective view of a base 62 of the arc-shaped positive plate 6 of the

rectifier 3 in FIG. 4. As shown in FIGS. 4-6, the arc-shaped positive plate 6 includes a base

62, which is generally a U-shaped body with two legs, i.e., a first leg 64 and a second leg 66.

The base 62 has multiple mounting holes 620, a fixing hole 622 and multiple through holes

!0 624. The fixing members 86 from the conduction plate 8 are passed through the mounting

holes 620 to connect the arc-shaped positive plate 6 and the conduction plate 8. Another

fixing member is passed through the fixing hole 622 and the housing 2 for securing the

arc-shaped positive plate 6 to the housing 2. Multiple positive-side diodes 68 are received in

the through holes 624 and are flush with upper and lower surfaces of the base 62 as shown in

!5 Fig. 5. In addition, the inner periphery 69 of the base 62 has a jagged shape for increasing the heat-dissipation surface of the arc-shaped positive plate 6. The material of the base 62 in this embodiment is aluminum.

[00301 As shown in Fig. 5, the second leg 66 extends from the first half portion 12 to the

second half portion 14. The second leg 66 is longer than the first leg 64. The first leg 64

has a first terminal 640, and the second leg 66 has a second terminal 660. The first aperture

5 and the second aperture 5a of the housing 2 as shown in FIG. 2 correspond to the first

terminal 640 and the second terminal 660, respectively. As shown in FIG. 5, the first

terminal 640 and the second terminal 660 are separated by an angle C ranging from 30 to 180

degrees with respect to a central axis A of the arc-shaped conducting plate . In another

embodiment, the angle C is from 30 to 90 degrees. In the embodiment shown in Fig. 5, the

angle C is about 69 degrees. Moreover, referring to FIG. 3, the first terminal 640 includes a

first screw 642, and the second terminal 660 includes a second screw 662. The first screw

642 and the second screw 662 protrude outwardly from the first leg 64 and the second leg 66

respectively and are fully covered by the housing 2, as best shown in FIG. 2. In this

embodiment, the first screw 642 and the second screw 662 protrude outwardly in the axial

direction of the circular housing 2. The first screw 642 and the second screw 662 are made

ofmetal.

[00311 Referring to FIGS. 4-5, the negative plate 7 is generally arc-shaped. The

negative plate 7 has multiple mounting holes 72 and multiple through holes 74. The fixing

!0 members 86 from the arc-shaped positive plate 6 are passed through the mounting holes 72

(the fixing members 86 are not shown in FIG. 4). Multiple negative-side diodes 70 are

received in the through holes 74 and are flush with upper and lower surfaces of the negative

plate 7. The negative plate 7 may be coupled to the housing 2 to make the ground

connection.

[00321 Referring to FIG. 3, the regulator 9 is located within the second half portion 14

and includes a microcontroller unit 90 and a receptacle 92. The regulator 9 extends under

the second leg 66 such that the receptacle 92 is coupled to the microcontroller unit 90 and

located between the first terminal 640 of the first leg 64 and the second terminal 660 of the

second leg 66. In other words, the second leg 66 is located between the microcontroller unit

90 and the receptacle 92. The receptacle 92 is configured to be electrically connected to a

battery, a power source, or any other electronic components, of the vehicle.

[00331 FIG. 7A is a front view of the insulated terminal structure 4 in FIG. 1, and FIG.

7B is a cross-sectional view of the insulated terminal structure 4 in FIG. 7A. Referring to

FIGS. 2, 7A and 7B, the insulated terminal structure 4 is partially received within the first

aperture 5 of the housing 2 as so to be coupled to thefirst screw 624 of the first terminal 640

in a first direction D1, i.e., the axial direction of the arc-shaped positive plate 6. In this

disclosure, the axial direction of the arc-shaped positive plate 6 refers to a direction that is

parallel to a central axis A of the arc-shaped positive plate 6. Specifically, the insulated

terminal structure 4 includes a connector 40 and an insulating sleeve 42. The connector 40

is made of metal, for example, S45C steel covered with zinc, and the insulating sleeve 42 is

made of insulated material, for example, polyphenylene sulfide (PPS) with graphite felt.

The connector 40 has an input end 44, an output end 45, and a middle section 46 between the

input end 44 and the output end 45. The input end 44 is cylindrical in shape, which matches

!0 the shape of the upper portion 50a of the first aperture 5. The input end 44 of the connector

40 in this embodiment includes a thread hole 48 therein for being coupled to the first screw

642. The insulating sleeve 42 surrounds both the middle section 46 and the input end 44 of

the connector 40. Also, the insulating sleeve 42 on the middle section 46 is in contact with

the rim surrounding the first aperture 5, thereby preventing unintended inward movement of

!5 the insulated terminal structure 4.

[00341 In accordance with embodiments of the present disclosure, the insulated terminal

structure 4' may be coupled to the first terminal 640 in a second direction other than the first

direction. As shown in FIG. 8, a perspective view of an insulated output assembly 1 for a

vehicle AC generator according to a second embodiment of the present disclosure, and FIG. 9,

an exploded view of the insulated output assembly 8 in FIG. 1, another insulated terminal

structure 4' is provided to be coupled to the first terminal 640 in a second direction D2, i.e., a

radial direction of the arc-shaped positive plate 6. The first direction D1 as shown in FIG. 2

is orthogonal to the second direction D2 as shown in FIG. 9. The configuration of the

insulated terminal structure 4' in this embodiment is different from that of the insulated

terminal structure 4 as shown in FIGS. 7A-7B. FIG. 10A is a front view of the insulated

terminal structure 4' in FIG. 8. FIG. 10B is a cross-sectional view of the insulated terminal

structure 4' in FIG. 10A. Referring to FIGS. 10A-10B, the insulated terminal structure 4' in

this embodiment includes a connector 40' and an insulating sleeve 42' surrounding a portion

of the connector 40'. The connector 40' has an input end 44', an output end 45' and a middle

section 46' between the input end 44' and the output end 45'. The insulating sleeve 42'

surrounds the middle section 46'. The insulating sleeve 42' includes a first body 420', an

annular recess 422' and a second body 424'. The annular recess 422' is formed between the

first body 420' and the second body 424'. As shown in FIG. 8, once the insulated terminal

structure 4' is coupled to the first terminal 640, the annular recess 422' of the insulated

!0 terminal structure 4' fits with the two blocks 23 of the housing 2 (see Fig. 2). At the same

time, the first body 420' is in contact with the outer surface of the lateral side 22 of the

housing2. The second body 424'is within the inner space of the housing 2, and the shape of

the second body 424' matches with the third section 53 of the first aperture 5. Thus, since

the insulated terminal structure 4' fits with the first aperture 5 along the second direction D2,

!5 it prevents unintended radial movement of the insulated terminal structure 4'. On the other

hand, the input end 44' is a sheet with a perforation 440' for the first screw 642 to pass through. As shown in FIG. 9, after the first screw 642 passes through the sheet, a bolt 49 is provided for securing the connector 40' onto the first screw 642 and for further preventing the axial movement of insulated terminal structure 4.

[00351 FIG. 11 is a perspective view of an insulated output assembly 1 for a vehicle AC

generator according to a third embodiment of the present disclosure, and FIG. 12 is an

exploded view of the insulated output assembly 1 in FIG. 11. Referring to FIGS. 11-12, the

insulated terminal structure 4 may be inserted into the second aperture 5a to be coupled with

the second screw 662 of the second terminal 660 of the second leg 66 in the first direction D1,

i.e., the axial direction. The configuration of the insulated terminal structure 4 is the same as

the insulated terminal structure 4 as shown in FIGS. 1-2 and 7A-7B, and thus is not repeatedly

described herein.

[00361 FIG. 13 is a perspective view of an insulated output assembly 1 for a vehicle AC

generator according to a fourth embodiment of the present disclosure, and FIG. 14 is an

exploded view of the insulated output assembly 1 in FIG. 13. Referring to FIGS. 13-14, the

insulated terminal structure 4' may be inserted into the second aperture 5a to be coupled with

the second screw 662 of the second terminal 660 of the second leg 66 in the second direction

D2, i.e., the radial direction. The configuration of the insulated terminal structure 4' is the

same as the insulated terminal structure 4' as shown in FIGS. 8-9 and 10A-10B, and thus is

not repeatedly described herein.

!0 [00371 Since the configurations of the insulated terminal structure 4, 4' as shown in FIGS.

7A-7B and 10A-10B are different from each other, the two types of the insulated terminal

structures 4, 4' preferably come with the vehicle AC generator when purchased by a

consumer.

[00381 In accordance with embodiments of the present disclosure, the insulated terminal

structure of an insulated output assembly is selectively coupled to either a first terminal or a

second terminal in either of two different directions, and the vehicle AC generator may

conform to different types of vehicles, thereby reducing relevant costs. Besides, retailers are

not necessary to purchase plural types of insulated output assemblies, thereby reducing

inventory costs.

[00391 Specific components of the insulated output assembly for a vehicle AC generator

have been described. It should, however, be apparent to those skilled in the art that many

more modifications besides those already described are possible without departing from the

inventive concepts herein. The inventive subject matter, therefore, is not to be restricted

except in the spirit of the present disclosure. Moreover, in interpreting the present disclosure,

all terms should be interpreted in the broadest possible manner consistent with the context.

In particular, the terms "comprises" and "comprising" should be interpreted as referring to

elements, components, or steps in a non-exclusive manner, indicating that the referenced

elements, components, or steps may be present, or utilized, or combined with other elements,

components, or steps that are not expressly referenced.

Claims

Lee and Li Attorneys-at-Law Docket No: V33688/AU7932 CLAIMS WHAT IS CLAIMED IS:

1. An insulated output assembly for a vehicle alternating current (AC) generator,

comprising:

a rectifier, comprising:

an arc-shaped positive plate having a first leg and a second leg each

having a terminal;

a regulator extending under the second leg; and

an insulated terminal structure selectively coupled to any one of the terminals in

either of two different directions.

2. The insulated output assembly of claim 1, wherein each of the terminals includes a

screw.

3. The insulated output assembly of claim 2, wherein the insulated terminal structure

comprises:

a connector having an output end and an input end selectively coupled to the

screw of one of the two terminals.

4. The insulated output assembly of claim 3, wherein the input end includes a thread hole

therein.

5. The insulated output assembly of claim 3, wherein the input end includes a sheet with a

perforation for the screw to pass through.

!5

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Lee and Li Attorneys-at-Law Docket No: V33688/AU7932

6. The insulated output assembly of claim 1, further comprising:

a housing accommodating the rectifier, the housing defining two apertures

corresponding to the two terminals, respectively and having two rims surrounding the

two apertures respectively.

7. The insulated output assembly of claim 6, wherein the insulated terminal structure is

received within one of two apertures and further comprises:

an insulating sleeve surrounding a portion of the connector, the insulating sleeve

being in contact with the rim surrounding the aperture receiving the insulated terminal

structure.

8. The insulated output assembly of claim 6, wherein each of the two apertures is formed

on both a top side and a lateral side of the housing.

9. The insulated output assembly of claim 1, wherein the two directions are orthogonal to

each other, and one of the two directions is parallel to a central axis of the arc-shaped

positive plate.

10. The insulated output assembly of claim 1, wherein the rectifier further comprises:

a negative plate; and

a connection coupled to the arc-shaped positive plate and the negative plate.

11. The insulated output assembly of claim 1, wherein the insulated output assembly is defined to have a first half portion and a second half portion, the second leg extends from the first half portion to the second half portion, and the regulator is located within the second half portion wherein each of the first half portion and the second half portion is generally in a semi-circular shape.

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Lee and Li Attorneys-at-Law Docket No: V33688/AU7932

12. The insulated output assembly of claim 11, wherein the regulator comprises:

a substrate;

a microcontroller unit disposed on the substrate; and

a receptacle coupled to the microcontroller unit and located between the two

terminals.

13. The insulated output assembly of claim 1, wherein the two terminals are separated by

an angle from 30 to 180 degrees with respect to a central axis of the arc-shaped positive

plate.

14. The insulated output assembly of claim 13, wherein the angle is from 30 to 90 degrees.

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