Alternator Rectifier Terminal Inclination for Cooling and Assembly
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Solution Overview
Problem
Conventional automotive alternator rectifiers face poor connection workability and increased resistance to cooling airflows due to projecting circuit board terminals, leading to reduced cooling performance and increased wind noise.
Innovation Solution
The alternator design improves connection workability by inclining radially inner end portions of circuit board terminals to facilitate assembly and reduces airflow resistance by integrating terminals within the molded resin portion, allowing simultaneous welding of first and second unidirectional conducting element bodies to the circuit board terminals, and positions the terminal connection portion to receive direct airflow for enhanced cooling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the radially inner end portions of circuit board terminals project radially inward from the molded resin portion, then the terminals can be positioned for connection, but the resistance to cooling airflows increases and cooling performance decreases
Solution Approach 1:
The circuit board terminals are inclined at a predetermined angle rather than extending radially inward. This angular orientation changes the dimension of terminal projection, allowing connection access from the axial direction while eliminating radial protrusion that blocks cooling airflow.
Solution Approach 2:
Instead of having terminals project radially inward to facilitate connection, the invention inverts the approach by inclining terminals at an angle and providing connection surfaces on the radially inner side, reversing the conventional projection direction while achieving both connection accessibility and airflow passage.
2Ease of operation
If the radially inner end portions of circuit board terminals project radially inward from the molded resin portion, then the terminals can be positioned for connection, but wind noise increases
Solution Approach 1:
The circuit board terminals are inclined at a predetermined angle rather than extending radially inward. This angular orientation changes the dimension of terminal projection, allowing connection access from the axial direction while eliminating radial protrusion that blocks cooling airflow.
Solution Approach 2:
Instead of having terminals project radially inward to facilitate connection, the invention inverts the approach by inclining terminals at an angle and providing connection surfaces on the radially inner side, reversing the conventional projection direction while achieving both connection accessibility and airflow passage.
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 enhances connection efficiency, reduces wind noise, and improves cooling performance by ensuring effective airflow around the rectifier components, thereby maintaining optimal operating temperatures.
Implementation Method 1
a rectifier that rectifies into direct current alternating current that has been generated in a stator
Implementation Method 2
a first heat sink; first unidirectional conducting element bodies that are disposed on a front surface of the first heat sink
Implementation Method 3
a fan on an end portion... rotation of the fan that is fixed to the end surface of the rotor
Data Source
Figure 1
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AI summary
A rectifier of an alternator according to the present invention includes: a first heat sink; first unidirectional conducting element bodies that are disposed on a front surface of the first heat sink so as to be spaced apart; a second heat sink that is disposed so as to be separated from the first heat sink; second unidirectional conducting element bodies that are disposed on a front surface of the second heat sink so as to be spaced apart; and a circuit board that has a circuit board terminal by which the first unidirectional conducting element bodies and the second unidirectional conducting element bodies are connected so as to constitute a bridge circuit, and a terminal connection portion is configured by respectively connecting first terminals of the first unidirectional conducting element bodies and second terminals of the second unidirectional conducting element bodies adjacently in a common plane with the circuit board terminal. Thus, connection workability between the first terminals of first unidirectional conducting element bodies and the circuit board terminal and between the second terminals of second unidirectional conducting element bodies and the circuit board terminal is improved.