Alternator Connector with Insulating Partitions
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Solution Overview
Problem
Existing polyphase rotary electrical machines, such as alternators for motor vehicles, face challenges with water and dirt penetration at the phase outputs and connector-dissipator assembly, leading to potential electrical issues and reduced efficiency due to inadequate insulation and complexity in the connector design.
Innovation Solution
A simplified connector design with an electrically insulating cover and a conductive heat sink, featuring internal partitions that match the shape of the connector sections, providing electrical insulation and air passage channels, and a compact, lightweight structure to enhance cooling and prevent water and dirt ingress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a complex connector design is used to provide insulation and protection, then reliability improves, but device complexity increases
Solution Approach 1:
The patent merges the connector and cover into a single integrated component. The connector body directly forms the housing structure, and the cover is integrated with the connector rather than being a separate assembly. This integration eliminates the need for complex multi-part connectors while maintaining insulation and protection functions through the unified structure.
Solution Approach 2:
The connector is designed to perform multiple functions simultaneously: it provides electrical connection, mechanical support, insulation, and protection against water and dirt. The integrated cover-connector assembly serves both structural and protective roles, reducing the need for separate specialized components and simplifying the overall design.
2Reliability
If additional insulation components are added to prevent water and dirt ingress, then reliability improves, but device complexity increases
Solution Approach 1:
The protective cover is merged with the connector structure, forming an integrated assembly. The cover is not a separate component but is directly formed as part of the connector housing, eliminating the need for additional insulation components while maintaining protection against water and dirt ingress.
3Productivity
If a compact structure is used to reduce size, then productivity improves, but manufacturing precision requirements increase
Solution Approach 1:
The internal partitions are merged with the cover structure, forming an integrated component rather than separate parts. The partitions are directly formed as part of the cover during molding, which simplifies alignment requirements and reduces manufacturing complexity while achieving the desired compact structure.
Solution Approach 2:
The cover is segmented into multiple functional zones by internal partitions that are integrated into the cover structure. These partitions create separate compartments for different electrical components while being formed as a single piece, maintaining compactness without requiring high-precision assembly of multiple parts.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution improves the insulation and cooling efficiency of the connector, reduces material usage, and prevents water and dirt from entering the assembly, thus enhancing the reliability and performance of the polyphase rotary electrical machine while maintaining compactness and ease of assembly.
Implementation Method 1
a heat sink in the form of a plate secured to the bearing and carrying first current rectifying elements
Implementation Method 2
internal circulation of a cooling fluid, here air
Implementation Method 3
This air circulation is carried out using the fans 102, 104 and makes it possible to cool the arrangement 1, the assembly 116, the bearings 105, 106 and the buns 39 of the stator 12
Data Source
Figure 1
Figure 2~3
Figure 4
AI summary
The invention relates to a multiphase rotary electric machine including a bearing (16, 18) provided with a plate (3) that is perforated for the passage of the phase outputs of the machine, of the type that comprises: an electrically conductive heat sink (9) bearing first current rectifying elements; second current rectifying elements (borne by the plate (3)); a connector (113) disposed between the heat sink (9) and the plate (3); and a protective cover on top of the heat sink/connector assembly. The outer periphery of the connector includes faces and hooks (114) for securing the phase outputs. According to the invention, the cover is provided internally with inner dividers which extend into the space defined by the securing portion of the hook and the corresponding face of the heat sink/connector assembly. The invention is suitable for motor vehicle alternators.