Abstract: A method of forming a stator core assembly for an electric machine includes providing a stator core having a plurality of radially extending slots, forming a flat wire pack having a plurality of continuous electrical wires, shaping the flat wire pack into a substantially cylindrical shape, and engaging the substantially cylindrically shaped flat wire pack with the stator core such that the continuous electrical wires are interlaced within the slots of the stator core.

Abstract: An alternator of the present invention includes a housing, a stator assembly mounted stationary within the housing, and a rotor assembly mounted rotatably within the housing in functional engagement with the stator assembly. An air gap extends annularly around the alternator between the rotor assembly and the stator assembly. The rotor assembly has a first end and a second end, and the air gap has a non-uniform thickness that varies along the axial length of the rotor assembly between the first and second ends of the rotor assembly. This non-uniform thickness is designed to avoid interference between rotor outer surface and stator inner surface at high rotor spin speed, but minimize the averaged air gap thickness for high alternator performance.

Abstract: A method of forming a stator core assembly for an electric machine includes providing a stator core having a plurality of radially extending slots, forming a flat wire pack having a plurality of continuous electrical wires, shaping the flat wire pack into a substantially cylindrical shape, and engaging the substantially cylindrically shaped flat wire pack with the stator core such that the continuous electrical wires are interlaced within the slots of the stator core.

Abstract: An alternator of the present invention includes a housing, a stator assembly mounted stationary within the housing, and a rotor assembly mounted rotatably within the housing in functional engagement with the stator assembly. An air gap extends annularly around the alternator between the rotor assembly and the stator assembly. The rotor assembly has a first end and a second end, and the air gap has a non-uniform thickness that varies along the axial length of the rotor assembly between the first and second ends of the rotor assembly. This non-uniform thickness is designed to avoid interference between rotor outer surface and stator inner surface at high rotor spin speed, but minimize the averaged air gap thickness for high alternator performance.

Abstract: A stator core assembly having an annular core defining an outside diameter, an inside diameter, and a plurality of radially projecting winding slots. A first electrical conductor and a second continuous electrical conductor are inserted within the winding slots circumferentially around the stator core. The conductors form a plurality of layers, each layer being defined as one substantially complete circumferential pass of the conductors around the stator core. Each of the conductors include a plurality of straight portions that lay within the winding slots, and a plurality of end loop portions that extend circumferentially to connect two of the straight portions. The length of the straight portions and end loop portions vary between the layers based upon the radial location of the particular layer within the stator core and a pre-determined axial height of the end loop portions.

Abstract: A stator core assembly having an annular core defining an outside diameter, an inside diameter, and a plurality of radially projecting winding slots. A first electrical conductor and a second continuous electrical conductor are inserted within the winding slots circumferentially around the stator core. The conductors form a plurality of layers, each layer being defined as one substantially complete circumferential pass of the conductors around the stator core. Each of the conductors include a plurality of straight portions that lay within the winding slots, and a plurality of end loop portions that extend circumferentially to connect two of the straight portions. The length of the straight portions and end loop portions vary between the layers based upon the radial location of the particular layer within the stator core and a pre-determined axial height of the end loop portions.

Abstract: An alternator comprising an inner housing, an outer housing mounted over the inner housing and a plurality of o-rings positioned between the inner housing and the outer housing thereby creating a sealed flow chamber having a first plenum, an axial jacket, a second plenum, a first passageway interconnecting the first plenum and the axial jacket, a second passageway interconnecting the axial jacket and the second plenum, an inlet extending from the first plenum, and an outlet extending from the second plenum. The first and second plenums are disk shaped cavities extending diametrically across the alternator, and the axial jacket is an annular jacket extending around the alternator. The first passageway is located diametrically across from the inlet and the second passageway is located diametrically across from the first passageway. The outlet is located diametrically across from the second passageway.

Abstract: An automotive alternator includes an inner housing assembly, an outer housing assembly mounted over the inner housing assembly, and an internal plate mounted within the outer housing assembly. The inner housing assembly, the outer housing assembly, and the internal plate define a sealed flow chamber. The flow chamber includes an inlet reservoir and an outlet reservoir located adjacent a first end, and a cross over reservoir located adjacent a second end. The inner housing assembly includes a plurality of radially extending axial fins. The fins extend outward from the sleeve toward the outer housing to define a plurality of axial flow channels. A first portion of the flow channels interconnects the inlet reservoir to the cross over reservoir and a second portion of the flow channels interconnects the cross over reservoir to the outlet reservoir.

Abstract: An alternator comprising an inner housing, an outer housing mounted over the inner housing and a plurality of o-rings positioned between the inner housing and the outer housing thereby creating a sealed flow chamber having a first plenum, an axial jacket, a second plenum, a first passageway interconnecting the first plenum and the axial jacket, a second passageway interconnecting the axial jacket and the second plenum, an inlet extending from the first plenum, and an outlet extending from the second plenum. The first and second plenums are disk shaped cavities extending diametrically across the alternator, and the axial jacket is an annular jacket extending around the alternator. The first passageway is located diametrically across from the inlet and the second passageway is located diametrically across from the first passageway. The outlet is located diametrically across from the second passageway.

Abstract: A golf ball handling apparatus comprises a hollow body for holding a plurality of golf balls, a passage between the body and the end of the apparatus, a ball control mechanism, a ball guide and legs for elevating one side of the body. The ball control mechanism includes a biased lever pivotally attached to the passage. A stop extends from the bottom of the lever into the passage and is moveable between an open and closed position as the lever is depressed and released. The lever is biased so that the stop is normally closed. Balls are retrieved from the playing surface by pressing the end of the device over the ball, forcing the ball into the passage. The ball moves the stop out of the way as it travels into the passage. In the closed position the stop partially blocks the passage in the body preventing balls from exiting. To dispense balls the lever is depressed, moving the stop to an open position allowing a golf ball to roll out of the passage onto the playing surface.

Abstract: A molded rotor assembly (20) including at least one molded fan (28), a method for making the same, and a vehicle alternator (160) using the molded rotor assembly (20) are disclosed. The rotor assembly (20) includes first and second pole pieces (24,26) aligned along a longitudinal axis (40) defining a region (122) between the pole pieces (24,26). Each pole piece (24,26) has an outboard axial face (69,71). At least one molded fan (28) is integrally molded to one of the axial outboard faces (69) of a pole piece (24). Preferably, a molded insert (22) is molded in the region (122) between the pole pieces (24,26) and is integral with the molded fan (28) to secure the molded fan (28) to the pole piece (24). Alternatively, anchoring recesses (241,245) are formed in an outboard face of a pole piece (224) with a molded fan (228) having anchoring portions (249,251) secured within the recesses (241,245) to retain the fan (228) to the outboard axial face.

Abstract: A molded rotor assembly (20) for a vehicle alternator and method for making the same are disclosed. The rotor assembly includes first and second pole pieces (24,26) aligned along a longitudinal axis (40), the pair of pole pieces (24,26) defining a region therebetween. A coil wire (46) is located in the region. The pole pieces (24,26) and a slip ring assembly (36) are mounted on a rotor shaft (38). The slip ring assembly (36) has a pair of slip rings (102,104) connected to a pair of terminals (96,98) which are attached to respective free ends of the coil wire (46) to form a pair of connections (126,128). A molded insert (22) is injection molded filling the region between the pole pieces (24,26) thereby encapsulating the connections (126,128) and the coil wire (96) and forming a smooth cylindrical periphery on the rotor assembly (20).

Abstract: A regulator and brush holder assembly having a regulator assembly attachable to an alternator adjacent to the alternator's slip rings and a housing attached to the regulator assembly. The housing has a brush holder portion and a regulator compartment enclosing the regulator circuit of the regulator assembly. The brush holder portion has a pair of spatially separated brush holder compartments and a pigtail chamber associated with each brush holder. The associated brush holder compartments and the associated pigtail chambers have an open end and a closed end and are connected by a slot. Brush terminals are attached to the housing and extend into the open end of the pigtail chambers. A carbon brush is slidably received in each brush holder cavity and its pigtail connection is connected to the associated brush terminal through the slot.

Abstract: An improved terminal for electrical connection to an alternator includes a connecting plate formed as portion of a radiator plate including recesses adapted to receive diodes for use in forming a rectifier bridge. The rectifier bridge assembly comprises a plastic housing that is insert molded over the radiator plate including louvers for passing cooling air past the diodes. The connector plate includes an opening to receive the stem of an enlarged headed fastener before the plastic body is formed around the radiator plate. Before molding, the bolt is pressed by a mold insert against the contact plate so the stem extends outwardly within an axially extending, circumferentially interrupted wall formed by the molding process.