Alternator Rectifier Heat Sink with Variable Ribs
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Solution Overview
Problem
Automotive alternators face challenges in maintaining high-strength and efficient cooling of rectifiers due to increased ambient temperatures and power generation demands, with existing heat sinks prone to cracking from stress concentrations and manufacturing defects during press-fitting of rectifying elements.
Innovation Solution
The design incorporates heat sinks with annular ribs of varying protruding heights around fitting holes, distributing stress uniformly and increasing the surface area for enhanced cooling, while also featuring through-holes and fins to improve cooling performance and structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If cooling fins have receiving holes and ribs formed therein, then cooling performance is improved, but the fins become prone to cracking due to stress concentration
Solution Approach 1:
The patent applies local quality by varying the thickness of the cooling fins in different regions. The fins are designed with non-uniform thickness distribution, where certain areas have increased thickness to provide additional strength and stress distribution capabilities, while other areas maintain thinner profiles for optimal cooling surface area. This localized variation in geometric properties allows the structure to simultaneously achieve both cooling performance and structural integrity.
2Volume of moving object
If the size of automotive alternator is reduced, then compactness is improved, but cooling capability is insufficient
Solution Approach 1:
The patent utilizes dimensional optimization by carefully controlling the thickness dimension of the cooling fins. The fins are designed with optimized thickness values that maximize the surface area available for heat dissipation within the constrained volume of the compact alternator. This dimensional approach allows the heat sink to provide sufficient cooling capability while maintaining a reduced overall size.
3Ease of manufacture
If rectifying elements are press-fitted into holes, then assembly is simplified, but cracks occur during press-fitting operation
Solution Approach 1:
The patent implements beforehand cushioning by designing the cooling fins with increased thickness in the regions where press-fitting operations will occur. This pre-reinforcement creates a cushioning effect that absorbs and distributes the stress generated during press-fitting, preventing crack formation. The thicker fin sections act as stress buffers that protect the overall structure from damage during assembly.
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 configuration prevents cracking, ensures high strength, and enhances cooling capabilities, effectively addressing the challenges of increased temperature and power demands in automotive alternators.
Implementation Method 1
a heat sink having a plurality of fitting holes, in each of which one of the rectifying elements is fitted
Implementation Method 2
enhancing the cooling capabilities
Data Source
AI summary
A rectifier of an automotive alternator includes a heat sink that has fitting holes, in each of which one rectifying element is fitted, and a major surface on which the fitting holes open. The heat sink also has substantially annular ribs, each of which is formed on the major surface around a corresponding one of the fitting holes. Each of the ribs has a first portion, which lies in an area on the major surface where a minimum distance between an inner edge of the heat sink defining the corresponding fitting hole and an outer edge of the heat sink defining an outline of the heat sink is smaller, and a second portion that lies in an area on the major surface where a minimum distance between the inner and outer edges is larger. The first portion has a greater protruding height from the major surface than the second portion.