Flexible Lead for Pressfit Diode Bridge Rectifier
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Solution Overview
Problem
The rigid connection between crimp connectors and diode leads in motor vehicle rectifier assemblies is prone to failure due to temperature cycling and vibration, leading to frequent failures.
Innovation Solution
A flexible conductor with one end connected to a conductive connector and the other end connected to a diode lead, along with an insulator with wings for enhanced electrical insulation, forms a more reliable connection within a rectifier assembly, which includes a heat sink and diode, and can be reinforced with a non-conductive polymer for additional support.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a rigid connection is used between crimp connector and diode lead, then electrical characteristics are maintained, but reliability deteriorates due to temperature cycling and vibration
Solution Approach 1:
The patent applies this principle by replacing the rigid crimp connector with a flexible conductor that has elongation capabilities. The flexible conductor can stretch and deform to accommodate thermal expansion and vibration without breaking, while still maintaining electrical conductivity. This resolves the contradiction by providing both reliability under environmental stress and adequate mechanical strength through material flexibility.
Solution Approach 2:
The patent changes the mechanical parameters of the conductor from rigid to flexible by selecting materials with appropriate elongation properties. The flexible conductor is designed with specific elongation characteristics that allow it to withstand temperature cycling and vibration. This parameter change enables the connection to maintain both reliability and sufficient strength by adapting to environmental conditions.
2Reliability
If a flexible conductor is used to improve reliability under temperature cycling and vibration, then connection reliability improves, but electrical characteristics may deteriorate
Solution Approach 1:
The flexible conductor is designed to maintain adequate electrical conductivity while providing the necessary mechanical flexibility. The material selection and construction ensure that the conductor can stretch without creating excessive resistance or signal degradation, thus maintaining acceptable electrical characteristics while improving reliability.
Solution Approach 2:
The flexible conductor likely uses composite material construction that combines materials with different properties - one providing flexibility and elongation, another ensuring electrical conductivity. This composite approach allows the conductor to simultaneously achieve both reliability under stress and adequate electrical performance.
3Reliability
If insulator with wings is added to enhance electrical insulation, then electrical insulation improves, but device complexity increases
Solution Approach 1:
The insulator with wings is integrated into the existing assembly structure, combining the insulation function with the mounting structure. The wings are designed to fit into or around existing components, merging the insulator with the overall assembly rather than adding a completely separate element. This reduces the impact on device complexity while achieving improved electrical insulation.
Solution Approach 2:
The insulator acts as an intermediary element that provides electrical insulation between components that would otherwise be in direct contact. The wings are designed to interface with existing structures, using the insulator as a mediator that fits into the available space and provides insulation without requiring major redesign of the overall assembly.
Data Source
AI summary
An improvement to a bridge rectifier assembly of the type used to convert alternating current produced by an motor vehicle alternator into direct current. The bridge rectifier assembly of this type comprises a heat sink, a plurality of pressfit diodes installed in the heat sink, and a plurality of terminals electrically connected to the motor vehicle alternator. The first end of a flexible conductor is mechanically and electrically connected to a conductive connector. The second end of the flexible conductor is mechanically and electrically connected to a lead of one of the plurality of pressfit diodes. The conductive connector is electrically connected to one of the plurality of terminals to complete an electrical connection between the one of the plurality of pressfit diodes and the one of the plurality of terminals.