Automotive Alternator Rectifier Circuit Board Segmented Resin Molding
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Solution Overview
Problem
Conventional automotive alternator rectifying apparatuses face poor moldability and increased costs due to complex terminal shapes and numerous mold seals, which complicate the insert-molding process of circuit boards.
Innovation Solution
The use of first and second resin-molded bodies, divided into front and rear portions, to hold terminals from opposite sides, eliminating the need for insert-molding and reducing mold sealing positions, thereby improving moldability and yield.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If terminals are insert-molded into a single resin-molded body, then electrical connection is achieved, but moldability deteriorates due to complex terminal shapes and numerous mold seals
Solution Approach 1:
The circuit board is divided into front and rear portions (first and second resin-molded bodies) that are molded separately and then assembled. Terminals are held between these two portions rather than being insert-molded into a single complex mold, simplifying the molding process and improving moldability while maintaining electrical connection reliability.
2Ease of manufacture
If terminals are held between first and second resin-molded bodies, then moldability is improved, but assembly complexity increases
Solution Approach 1:
The first and second resin-molded bodies are integrated by stacking them together to form a unified circuit board structure. This merging approach simplifies the overall assembly process compared to handling multiple separate components, while still benefiting from the simplified molding process of each individual portion.
Data Source
AI summary
The circuit board includes: a first resin-molded body; a second resin-molded body; and a plurality of terminals each including: a positive electrode terminal portion to which is connected a lead of the positive-side rectifying element to be connected thereto; a negative electrode terminal portion to which is connected a lead of the negative-side rectifying element to be connected thereto; and a trunk portion that links the positive electrode terminal portion and the negative electrode terminal portion. The plurality of terminals are each held between the first resin-molded body and the second resin-molded body so as to be separated from each other such that the trunk portion is disposed between mating surfaces of the first resin-molded body and the second resin-molded body, the positive electrode terminal portion is inserted through the second resin-molded body, and the negative electrode terminal portion is inserted through the first resin-molded body.