Vehicle Generator Rectifier Waterproof Terminal Seal
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Solution Overview
Problem
Conventional rotating electric machines for vehicles face water intrusion issues at the connection portion between the output terminal and external terminals, leading to potential corrosion due to gaps between the output terminal and cover members, which can allow water to enter and reach the connection parts.
Innovation Solution
The design incorporates an insulating member with an annular protruding part that elastically deforms to contact the battery terminal, creating a seal and preventing water intrusion through the space between the inner and outer surfaces of the through hole, thereby ensuring a waterproof connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional rectifier housing with output terminal is used, then the rectifier can be protected and connected, but gaps between the output terminal and cover members allow water intrusion leading to corrosion
Solution Approach 1:
An insulating member is introduced as an intermediary component between the battery terminal and the rectifier housing. This insulating member includes a sealing portion that contacts the outer peripheral surface of the battery terminal, creating a waterproof barrier that prevents water from reaching the connection part while maintaining electrical insulation.
Solution Approach 2:
The sealing portion of the insulating member is designed to be flexible, allowing it to elastically deform during assembly to ensure intimate contact with the battery terminal's outer peripheral surface. This flexibility compensates for assembly tolerances and ensures a reliable waterproof seal even with minor dimensional variations.
2Reliability
If the insulating member is designed with tight sealing, then waterproof performance improves, but assembly resistance increases
Solution Approach 1:
The sealing portion is designed with dynamic characteristics, allowing it to elastically deform during the assembly process to reduce insertion resistance. After assembly, the elastic recovery maintains intimate contact with the battery terminal, ensuring waterproof performance without requiring excessive assembly force.
Solution Approach 2:
The insulating member's sealing portion is designed with specific material properties and geometric parameters that allow it to change its deformation characteristics. By controlling the thickness, elasticity, and cross-sectional shape of the sealing portion, the design achieves optimal balance between assembly ease and sealing effectiveness.
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
This configuration effectively prevents water from reaching the connection part, enhancing waterproof performance and reducing assembly resistance while maintaining effective sealing even with assembly tolerance gaps.
Implementation Method 1
the protruding part is in contact with an outer peripheral surface of the battery terminal in such a state that the protruding part is elastically deformed
Data Source
AI summary
A rotating electric machine for a vehicle includes a rectifier fixed to an outer side of the frame member and constituting a rectification circuit which rectifies the alternating current generated by the stator; a battery terminal protruding from the rectifier and configured to be connected with a battery cable; an insulating member having a through hole in which the battery terminal is inserted; and a waterproof cap attached to the insulating member so as to cover a connection part of the battery terminal with the battery cable in a waterproof state. The insulating member includes an annular protruding part protruding inward from an inner peripheral surface of the through hole. The protruding part is in contact with an outer peripheral surface of the battery terminal in such a state that the protruding part is elastically deformed.