In the three-phase alternator according to the invention having the
characterising features of Claim 1 the advantage results that an integrated radial terminal, if desired also for all three-terminal studs B+, D+ and W normally present in a three-phase alternator, is possible, although an otherwise present blanking cap would, of course, of itself obstruct the radial departures of the staybolts to which the corresponding electrical lines of the vehicle wiring are to be connected.
However,, the invention succeeds in connecting the corresponding protective cap region in an elegant transition to a terminal block which is an integral part of the circuit board or terminal board itself, which is present in the rectifier, it being ensured furthermore, that the protective cap can be fastened simply and without any problem over the rectifier device, to be precise by clipping on.
The measures set forth in the subclaims result in advantageous further developments and improvements of the features specified in Claim 1. Of particular advantage is' the locking of the protective cap in the latched state with the rectifier device through the use of the elasticity normally present in injection-moulded plastic parts, by holding the base plate of the protective cap under tension by means of supporting pins which are supported on one of the circuit boards of the rectifier device. It is thus ruled out that the protective cap can become detached from the three-phase alternator even in the roughest use.
2307/otImU 17.04.1990 is Finally, it is advantageous that when the protective cap is slipped on its boundary edges surrounding the terminal block of the circuit board are received and held in the manner of a drawer in guides of the block, so that the circuit board takes over with its terminal block in this region the covering of the rectifier device which is otherwise fulfilled by the protective cap. In this arrangement. the cutout of the protective cap surrounding the terminal block of the circuit board extends over a considerable angular range, since in an advantageous embodiment all three terminal studs, integrated into the circuit board of the rectifier,, f or the D+,, B+ and W terminals are received by the terminal block.
Latching of the protective cap to the casing of the three-phase alternator, especially with one of the cooling plates of the rectifier device, takes place via at least three clipholders distributed over the circumference of the protective cap, inwardly projecting noses of which latch against correspondingly constructed opposite boundary edge regions of the positive cooling member of the rectifier device.
Drawing Exemplary embodiments of the invention are represented in the drawing and explained in more detail in the following description.
Fig. 1 shows a top view of a possible form of the circuit board consisting of a suitable insulating material (plastic), the cooling plates which are otherwise situated above and below the circuit board being removed; Fig. 2 shows the circuit board of Fig. 1 in a view from the left with a representation of the radially projecting terminal block region,, remaining parts being cut away; 23071ot/mil 17.04.1990 Fig. 3 shows a section along the line III-III of Fig. 2; Fig. 4 shows a section along the line IV-IV of Fig. 2 and Fig. 5 shows a section along the line V-V of Fig. 2, while Fig. 6 represents the rectifier device with mounted protective cap, so that the radially laterally projecting terminal block of the circuit board is visible, and Fig. 7 shows a side view from the left of the represen tation of Fig. 6, with the protective cap removed from the terminal block region, only this ter minal block region and the corresponding cutout of the protective cap being represented in each is case and the remaining parts being cut away.
Description of the exemplary embodiments The basic idea of the present invention consists in employing an appropriately integrated configuration of the circuit board between two cooling members of a rectifier device in a three-phase alternator both to realise the radial terminal for the electrical lines, for example of a vehicle electrical system, leading away from the alternator, and also to facilitate the fastening of the protective cap in a suitable way.
In this case, the basic construction of the three-phase alternator is undertaken in the manner known per se as explained, including the structure of the rectifier device, in the Utility Model G 8,,711,,417 already mentioned further above, that is to say with reference to the rectifier device by arranging the circuit board 10 shown in Fig. 1 in a sandwich-like fashion betweenmetallic upper and lower cooling plates (not represented) which extend parallel to the circuit board 10 and to one another at a distance. In this arrangement, the required number of positive diodes are inserted in a first 2307/ot/ma 17.04.1990 is positive cooling plate, and the required number of negative diodes are inserted in the negative cooling plate,, which is normally located behind seen from the mounted protective cap, the wirings (sic) of which diodes is then essentially achieved via the circuit board, for which purpose some terminals of the negative and positive diodes, to be precise the casing terminals., with the respective cooling plates and the other terminals led away from the cooling plates are led to corresponding terminal connections of the circuit board.
Consequently, except f or the region of the electrical terminal block 11 which projects radially to the left in the plane of the drawing of Fig. l. . the construction of the circuit board is of subordinate importance for the invention and also does not need to be explained in detail; visible in Fig. 1, for example, are crimp connectors 12 located outside on the edge of the circuit board, which after the mounting of the rectifier device on the three-phase alternator are electrically connected by means of corresponding lead wires to the stator winding. Furthermore, crimp connectors 13 located inside may be seen, which serve to receive rectifier diode terminals this too does not need to be mentioned further.
Shown in dashed lines in Fig. 1 is the internal course of web-like electrical conductors inside the plastic jacket of the circuit board 10, which consists of an appropriate insulating material, which conductors are also led to the electrical stud terminals of the terminal block ll,, resulting thereon in a first radially outwardly projecting screw stud terminal 14 f or the pole D+,, a second screw stud terminal 15 for the pole W and a prepared receiving region 16, which serves to receive the terminal pole D+ and this will then be dealt with briefly below. The entire region of the terminal block 11 projecting radially from the circuit board 10 is integrally formed with the material of the circuit board, that is to say it 23071ot/mil 17.04.1990 is is attached integrally to the latter, it being the case that it is not so much the terminal studs 14, 15 and 16 for the electrical terminal connections which projects radially outwards, but rather webs or separating plates 17, 18, 19 and 20 that surround these terminals and are therefore also protective, which project radially outwards and also have a prescribed axial extentr partly having arcuate bulges 17a, 20a, so that the nuts to be mounted on the screw studs can be screwed on and tightened by means of corresponding plug-in sockets on screwing tools. in this arrangement,, the entire region of the terminal block 11 also has a prescribed axial extent and thus forms an axial subapron, which ensures the protective covering of the rectifier device towards the outside in the terminal region, which is otherwise undertaken by the protective cap material now cut away (cutout 26).
Except for the terminal bolts for the terminal pole B+, the other terminal bolts are held in the terminal block by injection moulding with the plastic material of the circuit board and/or of the integral terminal block 11, f or example as shown in the cutouts of Fig. 4 and 5. Each of the terminal studs 14, 15 therefore comprises in an integral transition from the outwardly projecting threaded part a projecting angular shoulder 14a,, 15a, which merges once again further inside into a tapered pin 14b, 15b, against which, for example in the form of a tongue, the electrical, metallic conductor connection 21 coming f rom the circuit board then bears, or onto which it is fastened, in an electrically conductive fashion.
It is seen that the embedding of the shouldered terminal studs in the plastic material by injection moulding is undertaken in such a way that loosening or detachment is ruled out. Moreover. in this arrangement the middle angular projection 14a. 15a of each screw stud can further have an irregular outer contour. for example a quadrangular shape.
2307/ot/mil 17.04.1990 For special reasons. which serve f or locking of the B+ terminal which is particularly vibrationproof and bendproof, the B+ stud 22 is fastened by means of an angular retaining plate 23, which for its-part is connected via at least one rivet 24 directly to the positive cooling plate,, to the latter, the terminal block 11 in the circuit board then only further forming a pocket-like guide for receiving and supporting the B+ terminal set.
Since the electrical terminals, led away radially in this fashion from the circuit board 10, of the terminal block11 must naturally penetrate the boundary edge of a blanking cap 25 (cf. Fig. 7), which covers the rectifier device towards the outside and is mounted thereon, the blanking cap has this cutout 26 in the region of the terminal block 11 (Fig. 7), so that in other words in this terminal region the terminal board itself takes over the covering otherwise performed by the blanking cap and simultaneously ensures the electrical separation of the terminals.
A further special feature is hereby provided which consists in that, for the purpose of reliable anchoring and fixing of the protective cap 25, in particular in the transitional region to the terminal block 11 at the edge, mutual latching or anchoring means are provided which lock the two otherwise open or loose boundary edges 26a, 26b of the protective cap cutout 26.
The exemplary embodiment represented is constructed in such a way that, when the protective cap 25 is slipped onto the rectifier device, the boundary edges 26a. 26b of the cutout are received and locked in the manner of a drawer. Provided for this purpose in the region of the terminal block 11 are guide strips 27a, 27b, which are integral with the latter and form longitudinal openings 28 on both sides in which boundary strips constructed in a correspondingly complementary fashion on the boundary 1 2307/ot/mil 17.04.1990 edges 26a, 26b of the cutout 26 of the protective cap engage, so that at this point it is possible to insert the protective cap in the manner of a drawer. The guide strips 27a, 27b then simultaneously engage from behind the correspondingly thickened boundary regions of the protective cap opening, and thus lock the latter by impeding opening at the side. The region of the terminal block 11 then extends outwards with its corresponding protective webs 17, 18, 19f 20 beyond the arcuate course of the protective cap 25 as may best be gathered from the representation of the Fig. 6, in which it is also shown that a total of three screw studs 14, 15 and 22 for the corresponding three-phase alternator terminals project radially outwards.
is A further advantageous embodiment of the present inven- tion consists,, moreover, in that, for the purpose of locking the protective cap 25, the latter is latched with the rectifier device, to be precise in the special exemplary embodiment due to the fact that situated on the protective cap are clip holders which engage by means of noses on the boundary edges preferably of the immediately facing cooling member, that is to say the positive cooling member (not represented), by engaging the latter from behind.
It goes without saying of course that. as also in the case of the guide strips 27a. 27b of the terminal block11, the cl ip holders (or just the guide strips) can also be fastened in each case to the different part.
The preferred arrangement of the clip holders on the protective cap can best be seen from Fig. 6 and 7; middle webs 31,,. which have an inwardly directed nose-shaped projection 32. are liberated by means of incisions 30a. 30b on both sides in the radial wall region of the protective cap, being appropriately distributed over the circumference. Thus, where the incisions 30ai 3Qb on both 23071ot/mU 17.04.1990 sides terminate downwards or in the plane of the drawing of Fig. 7 seen towards the left. these webs are connected in an integral transition to the for example circular side wall. of the protective cap but. and this is not visible, are led further upwards or to the right In Fig. 7 over the region of the latching nose 32, it being the case furthermore. as shown in Fig. 6. that at this point of the upwardly led clip holder webs 31 the annular wall of the protective cap 25 are (sic) taken back in the form of a recess 32. so that it is possible when the protective cap is mounted and anchored, that is to say when the clip noses 32 have engaged the boundaries of the positive cooling member from behind, to grip with the finger between the recess 32 and the elongated web 31, and to press the latter outwards in the direction of the arrow A (Fig.6 (sic)), so that the latching noses come clear from the cooling member and the protective cap can once again be removed.
In this regard, importance is attached, moreover. to a further embodiment of the present invention which consists in that the protective cap 25 which is anchored on the positive cooling member via the webs 31 of the clip holders is seated on the rectifier device under tension, to be precise, in the preferred case, using the elasticity of the base plate of the protective cap. For this purpose. starting from the protective cap base, which is visible in Fig. 6 in top view from the other side, preferably from the peripheral boundary region, are inwardly directed support pins 34, which at the moment when the latching noses 3? engage the boundary edges of the positive cooling member from behind bear under pressure against the facing side of this cooling member, so that it is necessary to deform the base plate slightly in order for the latching noses actually to latch as well. This results in a deformation, even if only very small, of the protective cap. which is then seated firmly under tension and incapable of being detached by external 2307/ot/mU 17.04.1990 influences on the rectifier device. Removal is possible only if the webs 31 of the clip holders are pressed outwards, as mentioned further above.
is It is possible for there to be additionally arranged on the upper boundary edge 26c of the cutout 26, visible in Fig. 71 for the terminal block wall parts which project radially outwards and are integral with the protective cap, and which then evidently supplement the protective webs 17, 18, 19, 20 of the terminal block and protect the terminals in a suitable way; these projections can also have perforations, through which electrical connecting leads are led. This depends to the greatest possible extent on the special requirements and the respective place of installation of the three-phase alternator.
It remains to be pointed out generally that the circuit board itself has only a slight axial thickness, in any event only so much that the electrical terminals constructed flat in the form of webs can be embedded in it and mutually insulated while in the region of the terminal block the latter itself has a pronounced axial extent, that is to say forms a radial wall cutout over a prescribed axial length, from which the respective protective webs then project outwards integrally, and the guide strips are formed simultaneously on the two boundary edges. In this way, with this axial apron-like elongation the terminal block takes over the cutout region and the covering of the rectifier arrangements at this point, which are actually to be undertaken by the protective cap, which at this point,however, must have a -cutout for the radial pssage of the terminal block.
Finally,, it is possible for the protective cap additionally to be locked with the aid of screw f ixings on the rectifier device, for which purpose it is possible to form domes. which project from the terminal board in a direction towards the protective cap, and into which 230710t/MU 17.04.1990 bolts are then to be screwed from the side of the protective cap through bores in the latter.
All the features represented in the description, the claims and the drawing can be essential to the invention both individually in themselves and in any combination with one another. In particular, the main claim is a provisional attempt at formulation without knowledge of the prior art, which is not to be determined until an official search is undertaken. Moreover, the applicant reserves the right to reduce the features in the main claim.
7 CLAIMS is 1. Three-phase alternator for vehicles and the like, having a rectifier device, which consists of cooling plates, which are arranged parallel to one another and each receive positive or negative diodes with their casing, and also a circuit board (terminal board) c, insulating material, which is arranged between the cooling plates and in which there are embedded conductors for wiring the diodes to one another and lead wires of a stator winding of the three-phase alternator, characterised by a radially projecting terminal block (11), which is integrally formed on the circuit board (10) and comprises at least one stud bolt (14, 15, 22) projecting radially over the cooling plates, and has on both sides guides for boundary edges (26a, 26b) formed by a cutout (26) of a protective cap (25) surrounding the terminal block (11), the protective cap (25) being slipped over the rectifier -device and latched therewith.
2. Three-phase alternator according to Claim 1, charac terised in that the terminal block (11) comprises radially outwardly projecting stud bolts (14, 15) injection-moulded from the material of the circuit board (10),, and protective webs (17,, 18j, 19j, 20) preferably surrounding said bolts on both sides, which webs likewise project integrally radially outwards from the material of the circuit board (10).
3. Three-phase alternator according to Claim 1 or 2, 2307/ot/mil 17.04.1990 - is characterised in that apart from two terminal studs (14,, 15) f orming the terminal poles (D+ and W) a third terminal stud (20) forming the terminal pole (B+) is arranged in the region of the terminal block (11), which stud is inserted into a receptacle formed from radially projecting protective webs (19. 20) having an axial extent, and is supported by said receptacle, and is itself rigidly connected (riveted) to the positive cooling member by means of an angular retaining plate.
Three-phase alternator according to one of Claims 1 to 3, characterised in that the screw studs (14, 15) f or the D+ terminal and the W terminal, which are surrounded by the insulating material of the circuit board/terminal block,, in each case have a middle projecting shoulder (14a, 15a) and a tapered pin (14b, 15b).. which adjoins the latter and which simultaneously contacting electrical conductor tracks inside of the material of the circuit board (10) is likewise embedded in the latter.
5. Three-phase alternator according to one of Claims 1 to 4, characterised in that in conjunction with the circuit board (10) the terminal block (11) has axial longitudinal guide strips (27a, 27b) at the boundary, which receive and lock the facing boundary edges (26a, 26b) of the cutout (26) of the protective cap (25) in the manner of a drawer when the latter is slipped on.
6. Three-phase alternator according to one of Claims 1 to 5,, characterised in that the protective cap (25) is clipped to the rectifier device by means of integral latching webs (31) which can be bent radially outwards and form clip holders.
7 Three-phase alternator according to Claim 61 23071ot/mU 17.04.1990 is is - characterised in that the latching webs are formed by incisions on both sides from the side wall material of the protective cap (25), and have inwardly projecting latching noses (32) with which they engage boundary edges of the facing positive cooling member of the rectifier device from behind.
Three-phase alternator according to one or more of Claims 1 to 7, characterised in that the protective cap (25) is held under tension on the rectifier device due to the fact that making use of the elastic properties of the protective cap base, support pins (34) proceed therefrom in the peripheral region, and then rest under pressure on the facing positive cooling member of the rectifier device, if the latching noses simultaneously engage the cooling member boundary edges from behind.
9. Three-phase alternator according to one or more of Claims 1 to 8, characterised in that additional screw fixings (35) are provided for the protective cap, through which screws are led up to threaded openings in the rectifier device.
10. Three-phase alternator according to one of Claims 1 to 9, characterised in that the three screw stud terminals arranged in the region of the terminal block (11) are arranged one after another along the circumference of the circuit board in order to form the D+,, W and B+ terminals.
Three-phase alternator according to one of Claims 1 to 10, characterised in that for its part the protective cap has, in the cutout region for the terminal block (11), radially projecting material parts in addition to or supplementing the protective webs (17, 18, 19, 20) in the terminal block (11).
23071otImU 17.04.1990 f 16 - 12. Three-phase alternator according to one of Claims 1 to 11,, characterised in that the terminal block further has a pronounced axial extent in the form of a subapron which simultaneously forms a cover for the rectifier device at this point.
13. A three-phase alternator substantially as herein described with reference to the accompanying drawings.
Published 1991 at The Patent Office. Concept House. Cardiff Road. Newport. Gwent NP9 I RH. Further copies may be obtained from Sales Branch, Unit 6. Nine Mile Point. Cwmfelinfach, Cross Keys. Newport. NP I 7HZ. Printed by Multiplex techniques ltd, St Mary Cray, Kent.