Alternator system
AssigneeUnit Parts Company
InventorsMichael D. Ballard, Jianing Chen, Daniel Joseph Clark, Larry Joe Maddox
Life of this patent
Estimating the term…
Abstract
An improved alternator system for replacing an OEM Ford IAR alternator system. The improved alternator system includes a rectifier with increased heat dissipation qualities and decreased heat generation qualities and configured to maintain secure electrical connections. The alternator system is further configured to provide optimum electrical output by providing the rotor and the stator with additional turns or windings of heavier gauge wire whereby the alternator is capable of inducing a stabilized output current of at least about 52 amperes of current at about 1600 revolutions per minute of the rotor.
Claims18
A rectifier in combination with a Ford IAR alternator having a rotor and a plurality of stator windings housed in a frame, the frame having an external mounting surface to which a voltage regulator is mounted and electrically connected to the rotor and an internal mounting surface to which the rectifier is mounted and electrically connected to the stator windings, the rectifier comprising:
- a first plate defining a negative heat sink, the negative heat sink having a plurality of diode receiving openings formed therein;
- a second plate defining a positive heat sink, the positive heat sink electrically insulated from the negative heat sink and having a plurality of diode receiving openings formed therein;
- a plurality of negative diodes pressed fit into the openings of the negative heat sink;
- a plurality of positive diodes pressed fit into the openings of the positive heat sink, each of the positive diodes corresponding with and electrically coupled to one of the negative diodes and electrically connected to one of the stator windings;
- and
- a connector assembly including a connector box having a recess adapted to matingly receive a wiring harness, a B+ post having a first end secured to the connector box, a medial portion electrically connected to the positive heat sink, and a second end, and a terminal having a first end electrically connected to the B+ post and a second end including a pair of prongs disposed in the recess of the connector box.
A rectifier in combination with a Ford IAR alternator and a plurality of stator windings housed in a frame, the frame having an external mounting surface to which a voltage regulator is mounted and electrically connected to the rotor and an internal mounting surface to which the rectifier is mounted and electrically connected to the stator windings, the rectifier comprising:
- a first plate defining a negative heat sink, the negative heat sink having a plurality of diode receiving openings formed therein and having a uniform thickness greater than 5 mm;
- a second plate defining a positive heat sink, the positive heat sink having a plurality of diode receiving openings formed therein and having a uniform thickness greater than 5 mm;
- an insulator positioned between the positive heat sink and the negative heat sink so as to electrically insulate the positive heat sink from the negative heat sink, the insulator having a thickness less than 0.020 mm;
- a plurality of negative diodes pressed fit into the openings of the negative heat sink;
- a plurality of positive diodes pressed fit into the openings of the positive heat sink, each of the positive diodes corresponding with and electrically coupled to one of the negative diodes and electrically connected to one of the stator windings;
- and
- a connector assembly including a connector box having a recess adapted to matingly receive a wiring harness, a B+ post having a first end secured to the connector box, a medial portion electrically connected to the positive heat sink, and a second end, and a terminal having a first end electrically connected to the B+ post and a second end including a pair of prongs disposed in the recess of the connector box, the B+ post having a minimum diameter of five millimeters.
In a Ford IAR alternator having a rotor and a plurality of stator windings housed in a frame, the frame having an external mounting surface to which a voltage regulator is mounted and electrically connected to the rotor and an internal mounting surface to which a rectifier is mounted and electrically connected to the stator windings, the rectifier having a first plate defining a negative heat sink, a second plate defining a positive heat sink which is electrically insulated from the negative heat sink, a plurality of negative diodes electrically connected to the negative heat sink, a plurality of positive diodes electrically connected to the positive heat sink and corresponding with and electrically coupled to one of the negative diodes and electrically connected to one of the stator windings, and a connector assembly including a connector box having a recess adapted to matingly receive a wiring harness, a B+ post having one end electrically connected to a pair of prongs disposed in the recess of the connector box and another end electrically connected to the positive heat sink, the improvement comprising:
- the negative heat sink having a plurality of diode openings in which the negative diodes are pressed fit;
- and
- the positive heat sink having a plurality of diode openings in which the positive diodes are pressed fit.
Dependencies are inferred from the claim text.