Alternator brush holder

1. An alternator brush holder assembly defining perpendicular y and z axes, the z-axis extending substantially parallel to a rotational shaft of an alternator, the assembly comprising:

first and second brushes each having a shunt wire protruding from a lateral side of the brush; and

a housing having:

first and second brush chambers each extending approximately parallel with the y-axis and having the first and second brushes disposed therein;

first and second wire cavities extending from a brush-forward portion to a wire exit portion, the first wire cavity defining a centerline that extends in a direction forming an angle α with the z-axis; and

first and second slots respectively connecting the first and second wire cavities with the first and second brush chambers;

wherein the first and second shunt wires extend laterally through the respective first and second slots and then through the respective first and second wire cavities, and

wherein the first wire cavity has a z-axis dimension of Z, whereby the length of the first wire cavity is Z·(secant α) and

wherein the respective z-axis dimensions of the first and second wire cavities are at least 0.9 times the height (z-axis dimension) of the corresponding first and second brushes.

2. The alternator brush holder assembly according to claim 1 , further comprising a pair of springs disposed in respective ones of the brush chambers for biasing the brushes in the y-direction.

3. The alternator brush holder assembly according to claim 1 , wherein the z-axis dimension of the first wire cavity is less than approximately 0.97 times ((A/2) plus B), wherein A is the brush height and B is the distance between the brushes.

4. The alternator brush holder assembly according to claim 1 , wherein each wire cavity extends primarily in only one length-wise direction.

5. The alternator brush holder assembly according to claim 4 , wherein each wire cavity has a z-axis dimension of approximately 7.5 mm measured along the z-axis from the centerline of the respective brush/shunt wire connection.

6. The alternator brush holder assembly according to claim 1 , wherein a skewed exterior housing portion adjacent the skewed wire cavity approximately follows the skewed angle α so that an exterior space is created between the first and second wire cavities.

7. The alternator brush holder assembly according to claim 6 , wherein an electrical terminal is disposed in the exterior space between the first and second wire cavities.

8. The alternator brush assembly according to claim 1 , wherein the shunt wires of the first and second brushes have approximately the same routing through the respective first and second wire cavities.

9. The alternator brush assembly according to claim 1 , wherein the first and second wire cavities have approximately the same lengths, the first and second brushes have the same dimensions, and wherein the distance between the brushes is approximately the same as the height of one of the wire cavities.

10. The alternator brush holder assembly according to claim 1 , wherein the z-axis dimension of the first wire cavity is less than approximately 0.97 times ((A/2) plus B), wherein A is the brush height (z-axis dimension) and B is the distance between the brushes.

11. An alternator brush holder assembly defining perpendicular y and z axes, the z-axis extending substantially parallel to a rotational shaft of an alternator, the assembly comprising:

first and second brushes each having a shunt wire protruding from a lateral side of the brush; and

a housing having:

first and second brush chambers each extending approximately parallel with the y-axis and having the first and second brushes disposed therein;

first and second wire cavities extending from a brush-forward portion to a wire exit portion, the first wire cavity defining a centerline that extends in a direction forming an angle α with the z-axis; and

first and second slots respectively connecting the first and second wire cavities with the first and second brush chambers;

wherein the first and second shunt wires extend laterally through the respective first and second slots and then through the respective first and second wire cavities, the first wire cavity has a z-axis dimension of Z, whereby the length of the first wire cavity is Z·(secant α), and wherein the maximum z-axis dimension, for the first wire cavity, is approximately 1.45 times the height of the first brush.

12. An alternator brush holder assembly defining perpendicular y and z axes, the z-axis extending substantially parallel to a rotational shaft of an alternator, the assembly comprising:

first and second brushes each having a shunt wire protruding from a lateral side of the brush; and

a housing having:

first and second brush chambers each extending approximately parallel with the y-axis and having the first and second brushes disposed therein;

first and second wire cavities extending from a brush-forward portion to a wire exit portion, the first wire cavity defining a centerline that extends in a direction forming an angle α with the z-axis; and

first and second slots respectively connecting the first and second wire cavities with the first and second brush chambers;

wherein the first and second shunt wires extend laterally through the respective first and second slots and then through the respective first and second wire cavities, the first wire cavity has a z-axis dimension of Z, whereby the length of the first wire cavity is Z·(secant α), and wherein the second wire cavity defines a centerline that extends in a direction forming an angle β with the z-axis, whereby the length of the second wire cavity is Z·(secant β).