Alternator Rectifier Board with Engaging Heatsink Protrusions

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Solution Overview

Problem

Conventional alternators require additional parts for temporary fixing of the rectifier, increasing manufacturing costs and reducing assembly workability.

Innovation Solution

The alternator design incorporates a rectifier with positive-side and negative-side heatsinks and a circuit board, where one of the heatsinks or the circuit board features engaging holes and protrusions for press-fitting, eliminating the need for extra fixing parts and serving as an insulator between the heatsinks.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If additional parts are used for temporary fixing of the rectifier, then the rectifier can be fixed during assembly, but manufacturing costs increase and assembly workability decreases

Engineering Contradiction:

Improvefixing reliabilityVSAvoidnumber of parts

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The circuit board is designed to integrate both electrical connection functions and mechanical fixing functions. The fixing protrusions on the circuit board directly engage with the heatsinks, combining the support and fixation roles into a single component, thereby eliminating the need for separate temporary fixing parts.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The circuit board serves multiple functions simultaneously: it provides electrical connections between diodes, supports the heatsinks mechanically, and acts as an insulator. The fixing protrusions extend this multi-functionality by enabling direct mechanical attachment without requiring additional specialized fixing components.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If additional parts are used for temporary fixing of the rectifier, then the rectifier can be fixed during assembly, but manufacturing costs are pushed up

Engineering Contradiction:

Improvefixing reliabilityVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The circuit board integrates both electrical connection functions and mechanical fixing functions. The fixing protrusions on the circuit board directly engage with the heatsinks, combining the support and fixation roles into a single component, thereby eliminating the need for separate temporary fixing parts.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The fixing function is extracted from separate fixing parts and integrated directly into the circuit board structure. The fixing protrusions are formed as integral features of the circuit board, eliminating the need for additional fixing components and reducing part count.

Inventive Principle:

Principle #2Taking out (Extraction)

3Reliability

If additional parts are used for temporary fixing of the rectifier, then the rectifier can be fixed during assembly, but assembly workability is lowered

Engineering Contradiction:

Improvefixing reliabilityVSAvoidassembly workability

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The circuit board's fixing protrusions automatically engage with the heatsinks during assembly, providing self-fixing capability. This eliminates the need for separate fixing operations or additional components, allowing the assembly process to proceed more efficiently.

Inventive Principle:

Principle #25Self-service

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 design simplifies assembly, reduces manufacturing costs, and enhances workability by eliminating the need for additional fixing parts, while maintaining electrical insulation and controlling mechanical resonance.

Implementation Method 1

a positive-side and a negative-side heatsink that cool rectifier elements corresponding to each heatsink

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 2

a positive-side and a negative-side heatsink that cool rectifier elements corresponding to each heatsink

Methodology Applied

Scientific EffectHeat dissipation: Heat Sink

Implementation Method 3

the circuit board serves also as an insulator between the positive-side and the negative-side heatsink

Methodology Applied

Scientific EffectElectrical insulation: Dielectric

Implementation Method 4

one of either the positive-side and the negative-side heatsink or the circuit board is provided with engaging holes, and the other with engaging protrusions that are engaged with the holes

Methodology Applied

Scientific EffectMechanical fastening: Mechanical Fastener

Data Source

PatentUS9000635B2Alternator with engaged heat sinks and rectifier board

Publication Date: 2015.04.07 MITSUBISHI ELECTRIC CORP

AI summary

An alternator is provided with a rectifier including a positive-side and a negative-side heatsink that cool rectifier elements corresponding to each heatsink and a circuit board that holds the positive-side and the negative-side heatsink, wherein one of either the positive-side and the negative-side heatsink or the circuit board is provided with engaging holes, and the other with engaging protrusions that are engaged with the holes.