Compact rectifier bridge and method for manufacturing the same

#1. Technical Field

#The present invention relates to a rectifier bridge assembly for an air-cooled generator and a method of producing such a rectifier bridge.

#2. Description of the Related Art

#The present invention will now be described by way of example, with reference to the accompanying drawings, in which:

#FIG. 1 is a top view of a rectifier bridge according to the present invention.

#FIG. 2 is a top view of a positive diode heat sink of the rectifier bridge of FIG. 1.

#Referring now to the drawings wherein like reference numerals are used to identify identical components in the various views, FIG. 1 illustrates a compact rectifier bridge assembly 10 in accordance with one embodiment of the present invention. Rectifier 10 is provided to rectify the output voltage of an alternating current generator. It may be used as part of an air-cooled generator. Rectifier 10, however, can be used in other applications where similar benefits can be realized. The exemplary rectifier 10 may be used with a dual three-phase winding generator. Rectifier 10 is adapted to hold two sets of three (i.e., six) negative-side diodes and two sets of three (i.e., six) positive-side diodes. However, it will be apparent to those skilled in the art that the invention is not limited to such an arrangement. Rectifier 10 can be modified to hold more or fewer negative-side diodes and/or positive-side diodes depending upon the intended application of the rectifier assembly.

#Rectifier 10 in the illustrated embodiment is generally arc shaped and, therefore, is associated with a main axis 12. Axis 12 is depicted in side views and cross-sectional views of the present invention, such as FIG. 3. While rectifier 10 is generally arc shaped so as to fit within an air-cooled automotive generator with a generally annular cross-sectional shape. It will be appreciated by those skilled in the art, however, that other shapes, including annular, will also suffice.

#Rectifier 10 has a positive heat sink structure 16, a negative heat sink structure 18 that is axially spaced from the positive heat sink 16, and a terminal assembly 20 sandwiched between heat sinks 16, 18. FIGS. 2-4 depict positive heat sink 16. Positive heat sink 16 is generally arc shaped and may be made out of a thermally and electrically conductive material, such as aluminum. Positive heat sink 16 may include an arc shaped base 22, one or more cooling windows 24, an output terminal structure 25, one or more mounting bosses 26, one or more diode mounts 28, and one or more axial projecting spacers 29.