Patent ID: 7859158

Claim:
A connection structure between field coils and lead wires in a vehicle alternator, comprising: a rotor assembly, comprising: a rotor shaft, which is configured such that a slip ring is coupled to an outer circumferential surface of one end thereof and is provided with two guide grooves, which are formed in the outer circumferential surface in a longitudinal direction of the rotor shaft to be opposite each other and to have a predetermined depth, in order to enable lead wires, which are connected with the slip ring, to be seated and coupled thereto; a spool bobbin, which is wound by a rotor coil and is pressed and fitted into a middle portion of the rotor shaft; and rotor segments, each having a plurality of rotor poles 20 arranged in an axial direction, which are coupled to each other outside the spool bobbin to contain the spool bobbin; a rear fan provided with a through-hole for connecting the rotor shaft, two protrusion hubs, having a rectangular shape, which are formed to have a predetermined length so as to be opposite each other around the through-hole, wherein a hollow is formed in each of the protrusion hubs; and a rotor insulator configured such that a rear fan support, having a doughnut shape, is formed in a central portion thereof so as to be coupled to the protrusion hubs downstream of the rear fan, a through-hole for connecting the rotor shaft is formed in a central portion of the rear fan support, coupling parts are integrally formed so as to extend a predetermined length from respective side portions of the rear fan support, second slots for coupling the field coils are formed in respective first ends of the coupling parts, shaped guide pockets, which protrude to a predetermined height, are integrally formed on the coupling parts, and first slots for coupling the field coils, which are coupled to the second slots, are formed in respective first edge portions of the guide pockets; wherein a soldering or welding process is performed on twisted parts, which are formed by twisting the field coils and the lead wires around each other, the twisted parts are bent in the guide pockets of the rotor insulator, epoxy is applied to outer surfaces of the twisted parts and inner surfaces of the guide pockets, and the rear fan is coupled to a front of the rotor insulator so that inner surfaces of the protrusion hubs of the rear fan are in close contact with the guide pockets of the rotor insulator.