GB2364603A

GB2364603A - Terminal for alternator or electric motor

Info

Publication number: GB2364603A
Application number: GB0115992A
Authority: GB
Inventors: Roger Abadia; Laurent Thery; Sebastien Arrighi; Corinne Volle
Original assignee: Valeo Equipements Electriques Moteur SAS
Current assignee: Valeo Equipements Electriques Moteur SAS
Priority date: 2000-06-29
Filing date: 2001-06-29
Publication date: 2002-01-30
Also published as: FR2811144B1; ITRM20010370A1; KR20020002330A; GB0115992D0; KR100809095B1; FR2811144A1

Abstract

An alternator or alternator/starter has a terminal 100, and a circuit 220 mounted on a PCB 210. The spigot 100 is pushed through a hole in a metal strip 400, and a plastic mounting 300 is moulded around it. This supports the spigot and connects it to the circuit. The head 110 of the spigot may be non-circular.

Description

2364603 Rotating-electrical-machine electrical-linking module having

enhanced mechanical strengt The present invention relates to the modules for 5 connecting rotating electrical equipment, especially alternators or alternators/starters of motor vehicles.

The invention thus also relates to such rotating equipment in marine vehicles. It also relates to any type of rotating electrical machine.

10 Such connection modules are known, usually called "power outlet with integrated connector" or "power connector".

Present-day connection modules include a connection terminal made of the same material as a solid 15 part of the equipment in question, for example made of the same material as the heat sink in the case of an alternator.

However, the present-day connection modules have to include integrated circuits, and the connection 20 terminals made integrally with a solid piece prove to be difficult to link to such circuits.

The present-day arrangements therefore prove to be poorly compatible with circuits including a substrate and exposed chips.

The invention proposes to resolve this drawback, that is to say to propose a module for connecting rotating electrical equipment which easily integrates an electronic circuit, especially an integrated circuit.

This objective is achieved,' according to the 30 invention, by virtue of a rotat ing- electrical -machine electrical-linking module, comprising an electronic circuit, a support for this electronic circuit, as well as a connecting spigot linked electrically to the circuit, characterised in that it comprises a complementary assembly, separate f rom the support and from the spigot, which forms both an assembly for mechanical retention of the spigot and an electrical link between the spigot and the circuit.

According to other advantageous and non-limiting arrangements:

- the spigot includes a part with a non-circular periphery and the said complementary assembly comprises 10 means for clamping this part with non-circular periphery; - the complementary assembly includes a metal strip placed against the spigot and a plastic part, cast onto the strip and the spigot, the plastic part leaving 15 a part of the spigot uncovered; - the means f or clamping the part with non circular periphery include the plastic-part; - the plastic means which clamp the non cylindrical part of the spigot are cast onto this part; 20 - the complementary assembly includes a conducting strip pierced with a through-hole, the spigot includes an external shoulder, and the spigot passes through the hole, bearing by its shoulder against the borders of the hole; 25 - the means for clamping the part with non circular periphery include a metal strip pierced by a through-orifice into which the spigot is placed, the strip exhibiting at least one bend on the border of the hole 'which comes into abutment against the part with 30 non-circular periphery of the spigot; - the strip features two flanks folded on themselves and features an orifice passing through these two'flanks, into which the spigot is placed; the plastic part extends around the strip, leaving an outer surf ace of one of the two folds of the strip uncovered facing a part of the spigot which extends in projection from the complementary assembly; 5 - the strip forms four branches, three of which extend away f rom a central part of the strip and one of which is folded against a central region of the strip, the folded branch and the central region of the strip being traversed by the spigot, two strips, extending 10 away, featuring a part folded back against a non circular peripheral portion of the spigot, as well as a part extending beyond this fold extending away from the central region, the cast plastic material leaving uncovered the'third said branch extending away from the 15 strip; _ the complementary assembly includes a strip pierced by an orifice into which the spigot is placed, and the spigot is f ixed onto the strip by a riveting ring surrounding the spigot; 20 - the spigot is intended to constitute one terminal from among the positive, negative or live terminals of a motor-vehicle alternator; - the motor-vehicle alternator includes an electrical-linking module; 25 - the motor-vehicle alternator/ starter includes an electrical-linking module.

other characteristics, objects and advantages of the invention will emerge on reading the detailed description which will follow, given by reference to the

30 annexed figures, in which:

- Figure 1 represents a first variant of a connection module according to the invention, with wiring between a connection spigot and a' circuit of the module; _ Figure 2 represents a second variant of a connection module according to the invention, with a 5 linking bridge between a connection spigot and a circuit of the module; - Figure 3 represents a third variant in which an electrical link between a connection spigot and a circuit of the module is made via a lower f ace of a 10 complementary assembly according to the invention; - Figure 4 represents, seen from below, a channel f ormed in the complementary assembly of Figure 3; - Figure 5 represents a f ourth variant of the is invention in which a connection spigot is equipped with a circumferential spacer; - Figures 6 and 7 represent a fifth variant of the invention, with folded metal strip and riveted spigot; 20 - Figure 8 represents a sixth variant of the invention, in which a conducting strip features a folding with anti-rotational effect, according to the invention; - Figure 9 represents this same layout after a 25 stage of moulding of plastic, in vertical section; - Figure 10 represents a seventh variant of the invention in which a conducting strip is folded so as to prod. uce an anti-rotational effect and is furthermore embedded in plastid over its entire length.

30 The present connection modules principally include an electrically conducting spigot 100 intended to be engaged with a complementary connector, an electronic circuit 200 and a complementary assembly 300 having the role of mechanically holding the spigot 100 outwards and of connecting it electrically to the circuit 200.

The spigot used here is, for example, a power 5 spigot complying with the known reference M5 or M8, but could also consist of a standard screw.

The circuit 200 consists of a support 210, here a substrate, onto which the electronic components 220 are integrated.

10 The module further includes a metal strip 400 (or track 400) pierced by a through-orifice 410 in which the spigot 100 is lodged.

The connection module further includes the complementary assembly 300 'which is a plastic block 300 is which partially surrounds the spigot 100 and the strip 400.

The plastic is advantageously a PPS or a PBT.

In the variants of Figures 1 to 4, the spigot 100 here is a simple screw having a head 110 which is 20 non- cylindrical, here hexagonal or, for example, square, the threaded shank of which emerges from the plastic block 300, and the head 110 of which, in abutment against the borders of the orifice 410 of the strip 400, is embedded with this strip in the plastic block 300.

The plastic block 300 thus matches the screw head 110, and holds it, especially against any rotation of the spigot 100 about its axis.

In the embodiments of Figures 1, 2 and 5, the strip 400 extends transversely to the spigot 100 until 30 it leaves the block 300 on one of its sides via a free end. This free end forms a contact surface onto which is connected an electrical- linking element which extends as far as the card 200.

In Figure 1, this link is a metal wire welded, for example by ultrasonics or any other method, both to the strip and to the substrate 210 (it is also possible to fit several wires).

5 In Figure 2, the linking element is a rigid bridging piece which is brazed, bonded or electrically welded onto the strip 400. According to one variant, the strip 400 is extended by an elastic tab which is made to bear on the substrate (the substrate could also be 10 called "track").

The strip 400 is preferably surface-treated in order to allow ultrasonic wiring, brazing or electric welding or any other means of fixing and linking to the substrate.

is In the embodiment of Figures 3 and 4, the plastic block 300 and the strip 400 both extend laterally away from the spigot 100. The block 300 and the strip 400 thus form an elongate parallelepiped transversely to the spigot 100. The elongate 20 parallelepiped extends particularly to the side of the spigot 100, forming a lateral appendage to the spigot 100.

This appendage is traversed by a channel 320 parallel to the spigot 100.

25 The channel 320 opens out on two opposite faces of the block 300, that is to say on the face of the block from which the spigot 100 protrudes, and on the opposite face (called lower face of the block from now on). 1 30 The strip 400 covers over the said appendage formed by the block 300 on its lower face. To do that, the strip 400, as from the head 110 of the screw 100, describes a first fold parallel to the spigot 100 until it reaches the lower face of the plastic block, then a second fold at 900 so as to extend along the lower face of the appendage.

In vertical section, that is to say in section 5 parallel to the axis of the spigot 100, the strip 400 therefore forms a staircase the upper level of which is traversed by the spigot 100 and the lower level of which partially covers over the lower face of the plastic appendage.

10 The strip 400, on this lower face, features a second orifice 420 with diameter slightly greater than that of the channel 320, which borders the lower outlet of this channel 320.

The inner plastic walls of the channel 320 thus 15 extend into the orifice 420 of the strip, forming an insulating plastic insert over the thickness of the strip 400.

The strip 400 thus forms a lower contact surface of the block, against which upper contacts of the 20 circuit 200 are positioned.

The substrate board 210 is fixed against the strip 400 by screw fixing through the channel 320 and a through-orifice of the substrate.

In these various embodiments, the spigot 100 is 25 held mechanically by the plastic block 300, which does not transmit any mechanical force to the substrate 210.

In particular, the retaining of the terminal 100 against a rotational force is taken up by the block 300, without stressing the substrate.

30 The spigot or terminal 100, which here consists of a standard screw, may also feature a shank with no screw thread. The complementary connector is then typically a contact clamp, a socket, or another push-on type connection element.

In the embodiment of Figure 5, the spigot 100 is surrounded by a tubular spacer 500 which extends into 5 the plastic block 300 until it comes into abutment against the strip 400. The spacer also extends out of the block, around a portion of the shank of the spigot 100.

The spacer 500, here sliding on the spigot, may 10 also be screwed onto it. The spacer 500 may also consist of a bush, made of the same material as the strip 400. The spacer is made of metal.

The complementary contact clamp may also be supported by way of a spacer coming from this contact 15 clamp itself.

The present spacer 500 can be put in place before the moulding, so that the plastic comes to match it upon moulding, or be put in place after moulding, its housing having been reserved.

20 In the case in which the spacer 500 is free to slide on the spigot 100, a screw-type connector is engaged on the free end of the spigot 100 and comes to bear on the spacer so as to cause it to bear against the strip 400. The strip 400 is then in its turn made to 25 bear against the head 110 of the spigot 100.

In order to produce the above-described assemblies, the spigot 100 is inserted into the strip 400 and then the plastic block 300 is cast onto the spigot and the strip. 1 30 In Figure 6, the spigot 100 also constitutes a rivet passing through the strip 400, this riveting sufficing to hold the spigot against a rotation thereof.

The spigot 100 can also be f ixed onto the strip 400 by being push-fitted. In this case, the antirotational effect of the spigot is achieved by having this spigot push-fitted into the strip 400. It can also 5 be pushfitted into the plastic block 300.

In the variant of Figure 6, the strip 400 is folded onto itself and the spigot simultaneously passes through these two folds.

Furthermore, the plastic block 300 here matches 10 the strip 400 without coming into contact with the spigot 100. To do that, the strip 400 is embedded in the plastic with a cylindrical reservation, not represented here, which is placed in the extension of the orifice 410 of the strip before the plastic is cast, then 15 withdrawn after the plastic has hardened. Thus a reservation 340 is obtained with a diameter slightly greater than that of the orifice.

The spigot 100 is then put in place in this reservation 340, separated from the inner walls of this 20 channel-forming reservation by a space. The spigot 100, which also forms a rivet, exhibits the shape of a shank the head 110 of which comes into lower abutment against the strip 400.

The spigot 100 is push-fitted into the strip 400 25 from below, that is to say inserted into this strip by the connection end of the spigot 100.

The spigot 100 is then inserted into the orifice 410 by its lower face, and then receives a riveting ring 120 via its ftee end. This ring 120, here of metal, then 30 comes into abutment against the upper borders of the strip 400. It is also possible to provide a spigot 100 which has a shoulder turned downwards and which is riveted from the bottom.

The riveting ring 120 here forms a shoulder turned towards the free end of the spigot loo, this shoulder projecting above the block 300.

In this embodiment, the spigot 100 is chosen in S a final assembly stage, which makes it possible to assemble the strip 400 and the block 300 before having to choose the spigot 100.

In the embodiment of Figures 8 and 9, the strip 400, here again, features two folds brought one against 10 the other and traversed by the spigot 100.

The spigot 100, here again, features a head the upper face of which comes into abutment against one of the folds of the strip.

Furthermore, the head of the spigot 100, here 15 again, is a head 110 with a non-cylindrical, here hexagonal, periphery. In order to lock this head 110 in rotation, the strip 400 forms two wings folded against the hexagonal head extending from the central region of the strip 400 which is traversed by the spigot.

20 More precisely, the strip 400 features, in side view with respect to the spigot 100, an upturned-U part, the vertical bars of which frame the head of the spigot 100, so as to complement it, and the bottom of the U of which is traversed by the shank part of the spigot.

25 This strip 400 initially exhibits the shape of a flat cross having a central region and four branches in the form of flat wings. A first wing is folded onto the central region of the cross so as to double the thickness of this central region towards the top of the 30 strip, and thus to form a reinforced part for receiving the spigot 100.

Among the three remaining branches, two diametrally opposite side branches are folded towards one another in order to form the branches of the previously described U. These two branches, after their part intended to border the head, then extend substantially radially to the spigot 100.

The fourth branch of the strip 400, for its part, remains in the extension of the central region, so as to form an electrical-contact surface.

The strip 400 is first of all shaped, then receives the spigot 100. Once the spigot has been put in 10 place, the block 300 is cast over the assembly. The block 300 completely surrounds the two branches which border the head of the strip 400 so as to ensure that these branches are held against rotation.

The block 300 does not cover the whole of the 15 length of the fourth branch, which is linked later to the circuit 200. The branch forming the upper fold on the centre of the strip 400 presents its upper face uncovered towards the free end of the spigot 100.

The plastic of the block 300, to that end, comes 20 flush with this upper face without covering it over at the time of casting.

The upper fold thus forms a local excess height of the strip, which remains uncovered around the periphery of the spigot 100.

This contact surface is able to receive a complementary connector engaged over the spigot 100.

Thus, the electrical contact of this connector is formed directly on the strip 400.

As can be seen 'in Figure 9, the plastic 30 overmoulding further features a reservation 360 opposite the lower face of the head 110 of the spigot 100, allowing the spigot 100 to turn in and be extracted from the block 300 after moulding.

In the variant of Figure 10, the head of the spigot 100 this time is overmoulded. The strip 400 features the same U-shaped geometry which surrounds and complements the head 110 of the spigot 100. However, the 5 strip does not have such a central fold. The block 300 extends above the central region of the strip 400.

In the variant of Figure 10, it is therefore no longer necessary to take care as to the caulking of the plastic, in contrast to the other overmouldings of the 10 head of the spigot which are adopted in the case of Figures 1 to S.

In this embodiment, the spigot 100 is equipped with a circumferential spacer 500 which borders it in and outside of the block 300, this spacer extending from 15 the strip 400 until it projects out of the block 300 with the spigot 100.

In the variant of Figures 8, 9 and 10, retaining features are also provided on the head of the spigot, which are able to interact with complementary 20 arrangements of the strip 400. These arrangements, preferably clipping elements, for example, hold the head of the spigot while the plastic is being moulded.

These assemblies advantageously form the interface between the electronic circuit 200 and a 25 network external to the rotating electrical equipment. These assemblies are also suitable for connecting between the electronic circuit 200 and another part of the same rotating equipment.

The spigot 100 thus forms a terminal which can 30 be a positive or negative terminal, or a live terminal for an alternator, for example in the case of a module separate from the alternator.

Claims

1. Rotating-electrical-machine electrical-linking module, comprising an electronic circuit (200), a 5 support (210) for this electronic circuit, as well as a connecting spigot (100) linked electrically to the circuit (200), characterised in that it comprises a complementary assembly (300, 400), separate from the support (210) and from the spigot (100), which forms 10 both an assembly for mechanical retention of the spigot (100) and an electrical link between the spigot (100) and the circuit (200).

2. Module according Claim 1, characterised in that 15 the spigot (100) includes a part with a non-circular periphery (110) and in that the said complementary assembly (300, 400) comprises means for clamping this part with non-circular periphery (110).

20

3. Module according to any one of the preceding claims, characterised in that the complementary assembly (300, 400) includes a metal strip (400) placed against the spigot (100) and a plastic part (300), cast onto the strip (400) and the spigot (100)., the plastic part 25 leaving a part of the spigot (100) uncovered.

4. Module according to Claims 2 and 3 in combination, characterised in that the means for clamping the part with non-circular Lperiphery (110) 30 include the plastic part (300).

S. Module according to Claim 4, characterised in that the plastic means (300) which clamp the non- cylindrical part (110) of the spigot (100) are cast onto this part.

6. Module according to any one of the preceding 5 claims, characterised in that the complementary assembly (300, 400) includes a conducting strip (400) pierced with a through-hole (410), the spigot (100) includes an external shoulder, and the spigot passes through the hole (410), bearing by its shoulder against the borders 10 of the hole (410).

7. Module according Claim 2, characterised in that the means for clamping the part withnon-circular periphery (110) include a metal strip (400) pierc, ed by a 15 through-orifice (410) into which the spigot (100) is placed, the strip (400) exhibiting at least one bend on the border of the hole (410) which comes into abutment against the part with non-circular periphery (110) of the spigot (100).

8. Module according to Claims 3, 4, 5, 6 or 7, characterised in that the strip (400) features two flanks folded on themselves and features an orifice (410) passing through these two flanks, into which the 25 spigot (100) is placed.

9. Module according to Claim 8 in combination with Claim 3, characterised in that the plastic part (300) extends 'around the strip (400), leaving an outer surface 30 of one of the two folds of the strip (400) uncovered facing a part of the spigot (100) which extends in projection from the complementary assembly (300, 400).

10. Module according to Claims 3, 7 and 8 in combination, or according to Claims 3, 7, 8 and 9 in combination, characterised in that the strip (400) forms four branches, three of which extend away from a central 5 part of the strip (400) and one of which is folded against a central region of the strip (400), the folded branch and the central region of the strip (400) being traversed by the spigot (100), two strips, extending away, featuring a part folded back against a non- 10 circular peripheral portion (110) of the spigot (100), as well as a part extending beyond this fold extending away from the central region, the cast plastic material leaving uncovered the third said branch extending away from the strip (400)

11. Module according to any one of the preceding claims, characterised in that the complementary assembly (300, 400) includes a strip (400) pierced by an orifice (410) into which the spigot (100) is placed, and in that 20 the spigot (100) is f ixed onto the strip by a riveting ring (120) surrounding the spigot (100).

12. Module according to any one of the preceding claims, characterised in that the spigot (100) is 25 intended to constitute one terminal from among the positive, negative or live terminals of a motor-vehicle alternator.

13. Motor-vehicle alternator, characterised in that 30 it includes an electrical- linking module according to any one of Claims 1 to 12.

14. Motor-vehicle alternator/starter, characterised in that it includes an electrical-linking module according to any one of Claims 1 to 12.

15. A rotating- electrical -machine electrical -linking module substantially as herein described with reference to the accompanying drawings.

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