Rectifier Package Heat Dissipation via Segmented Thermal Paths
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Solution Overview
Problem
Current rectifier and heat sink configurations in dynamoelectric machines, such as alternators in motor vehicles, fail to adequately dissipate heat when the output current exceeds 200 amps, leading to unreliable component temperatures.
Innovation Solution
A rectifier design featuring an end frame with negative diodes, a positive heat sink with positive diodes, and a terminal assembly with conductive and heat dissipative straps that conduct heat from both types of diodes, enhanced by airflow through radial and axial vents and fins, effectively radiating heat from the components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If conventional rectifier and heat sink configurations are used, then the structure is simple and easy to manufacture, but heat dissipation is insufficient when current exceeds 200 amps
Solution Approach 1:
The rectifier is divided into separate positive and negative sections with dedicated heat sinks for each polarity. Positive diodes are mounted on a positive heat sink while negative diodes are mounted on a negative heat sink, allowing independent thermal management of each section. This segmentation enables more effective heat dissipation pathways for high current applications.
Solution Approach 2:
The patent introduces radial vents in addition to axial airflow pathways, adding a radial dimension to the cooling system. This multi-dimensional approach to airflow (both axial and radial components) significantly enhances heat dissipation capacity compared to conventional single-direction cooling.
2Power
If high current levels exceed 200 amps, then the alternator output capacity increases, but component temperatures become unsafe and unreliable
Solution Approach 1:
Dedicated heat sink structures serve as thermal intermediaries between the diodes and the cooling air. These heat sinks provide large surface areas for heat transfer, efficiently conducting heat away from the diodes and dissipating it to the atmosphere through axial and radial vents, thereby maintaining safe operating temperatures.
Solution Approach 2:
The patent employs forced air cooling through strategically positioned axial and radial vents that channel cooling airflow directly over the heat dissipation surfaces. This pneumatic cooling system efficiently removes heat from the rectifier components, enabling safe operation at high current levels exceeding 200 amps.
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 significantly improves heat dissipation, maintaining safe and reliable component temperatures even at high current levels, enhancing the alternator's performance and longevity.
Implementation Method 1
The end frame 12 conducts heat from the negative diodes 14 which is then radiated to the atmosphere. The positive heat sink 26 conducts heat from the positive diodes 24. The straps 48 conduct heat from the negative diodes 14 and the positive diodes 24 into the terminal assembly 44.
Implementation Method 2
heat from the diodes is transferred to the carrier plates and to the fins where the heat is radiated to the atmosphere
Implementation Method 3
Cooling air is urged through the rectifier to radiate heat from the end frame, the positive heat sink, and or the straps
Data Source
AI summary
Disclosed is a dynamoelectric machine having improved heat dissipation capabilities. The dynamoelectric machine includes a three-phase stator winding with a rectifier assembly electrically connected to the stator winding. The rectifier assembly includes an end frame having at least one negative diode contained therein and a positive heat sink which has at least one positive diode disposed therein. Connecting the negative diodes and positive diodes is a terminal assembly. The terminal assembly includes one or more electrically conductive and heat dissipative straps. The straps electrically connect one or more negative diodes and one or more positive diodes. Also disclosed is a method for dissipating heat from a rectifier of a dynamoelectric machine.