Starter contactor incorporating an electronic control circuit, and a vehicle starter having such a contactor

• US 6,049,263 A
• Filed: 09/05/1997
• Issued: 04/11/2000
• Est. Priority Date: 09/06/1996
• Status: Expired due to Term

• Current Assignee: Valeo Equipements Electriques Moteur (Valeo SE)
• Original Assignee: Valeo Equipements Electriques Moteur (Valeo SE)
• Inventors: Vilou, Gerard
• Primary Examiner(s): Gellner, Michael L.
• Assistant Examiner(s): Nguyen, Tuyen T.
• Application Number:
  US08/924,112
• Time in Patent Office: 949 Days
• Field of Search: 335/126, 335/128, 335/131, 290/38 R, 290/48
• US Class Current: 335/126
• CPC Class Codes: F02D 2400/18 Packaging of the electronic circuit in a casing
• CPC Class Codes: F02N 15/067 the starter comprising an electro-magnetically actuated lever
• CPC Class Codes: H01H 50/021 structurally combining a relay and an electronic component, e.g. varistor, RC circuit auxiliary switch inserting resistor during closure H01H50/543
• CPC Class Codes: H01H 50/023 Details concerning sealing, e.g. sealing casing with resin
• CPC Class Codes: H01H 51/065 Relays having a pair of normally open contacts rigidly fixed to a magnetic core movable along the axis of a solenoid, e.g. relays for starting automobiles details H01H50/20

Abstract

A motor vehicle starter has a contactor of the type that includes an electronic control circuit, which includes a printed circuit board in the form of a disc with a central hole through which the body of the control rod of the contactor passes. The electronic components of the control circuit are carried by the circuit board, which is located in an axial position within the interior of the pot-shaped end cap of the contactor, between the fixed core and the movable contact of the contactor. The electronic control circuit is mounted within a protective housing which is arranged inside the end cap, between the fixed core and the movable contact, and this housing also has electrical connection facilities.

Claims

1. A motor vehicle starter contactor, comprising:

a casing comprising a hollow annular cylindrical armature having an open front end and a hollow end cap secured on the front end of the armature, the end cap having a base portion and a lateral skirt portion extending from the base portion and defining within the end cap an internal chamber open towards the interior of the armature, the casing defining a contactor axis;

a pair of fixed power contact terminals carried by the base portion of the end cap;

an axially movable contact within the internal chamber, a control rod extending axially in the internal chamber and carrying the movable contact;

a fixed core in the form of a disc mounted radially in the front end of the armature, the fixed core having a central hole mounting the control rod for axial displacement of the control rod therein, wherein the control rod can displace the movable contact into and out of cooperation with the fixed power contact terminals;

a movable core, with the armature mounting the movable core within the armature for axial displacement of the movable core wherein the movable core acts on the control rod to effect said axial displacement of the control rod;

a solenoid winding mounted in the armature for actuating the movable core in said axial displacement thereof; and

an electronic control circuit for the contactor, the circuit comprising a disc-shaped support having a central through hole, the support being located within the end cap in an axial position between the fixed core and the movable contact, the control circuit further including electronic components carried by the support, wherein the contactor further includes a housing disposed within the end cap in a location in said internal chamber between the fixed core and the movable contact, the electronic control circuit being disposed within the housing wherein to be protected by the housing; and

the contactor further including electrical connection means carried by the housing, wherein the housing has a transverse front wall and a cylindrical side wall extending from the front wall to define a generally cylindrical housing chamber within the housing, the electronic control circuit being mounted within the housing chamber, and the housing chamber having an open rear end adjacent to the front face of the fixed core.

2. A contactor according to claim 1, wherein the side wall of the housing has an axial rear end and a radial flange at said rear end, the flange bearing against the transverse front face of the fixed core.

3. A contactor according to claim 2, wherein the transverse front face of the fixed core defines a first annular surface, the end cap defines a second annular surface in facing relationship with the first annular surface, and the end flange of the housing is interposed axially between the first and second annular surfaces.

4. A contactor according to claim 1, wherein the side wall of the housing includes locating means for locating the support of the electronic control circuit within the housing.

5. A contactor according to claim 1, wherein the transverse front wall of the housing defines at least one aperture, the electrical connection means comprising electrical connecting elements extending through the at least one aperture.

6. A contactor according to claim 5, having an electrical connecting element in the form of a connecting tag, the support of the electronic control circuit having a front face and the tag extending axially forward from the front face of the support.

7. A contactor according to claim 5, having an electrical connecting element in the form of a wire, the support of the electronic control circuit having at least one through hole, the wire extending axially from the solenoid winding and through said hole in the support.

8. A contactor according to claim 5, wherein the housing includes at least one electrically insulating element in the transverse front wall of the housing, the at least one aperture being formed in the at least one insulating element.

9. A contactor according to claim 8, wherein the transverse front wall of the housing has at least one through hole, the at least one insulating element comprising a component fitted in the at least one through hole.

10. A contactor according to claim 8, wherein the transverse front wall of the housing is made of an electrically insulating material and defines at least one through hole therein constituting said at least one aperture for the passage of an electrical connecting element therethrough.

11. A contactor according to claim 5, wherein at least one electrical connecting element that extends through the transverse front wall of the housing also extends axially through the base portion of the end cap.

12. A contactor according to claim 8, wherein at least one electrical connecting element that extends through the transverse front wall of the housing also extends axially through the base portion of the end cap, the electrically insulating element including an extension extending axially towards the end cap, the base portion of the end cap defining a seating complementary to and receiving the extension, the corresponding electrical connecting element extending axially through the extension and seating.

13. A contactor according to claim 1, wherein the housing further includes a central guide sleeve portion, with the control rod extending through the sleeve portion to be guided by the sleeve portion in axial sliding movement.

14. A contactor according to claim 1, wherein the transverse front wall of the housing has an outer face, the movable contact being so disposed as to bear axially against the outer face of the transverse front wall of the housing in a rest position of the contactor.