Bridge rectifier

• US 4,606,000 A
• Filed: 03/27/1985
• Issued: 08/12/1986
• Est. Priority Date: 03/27/1985
• Status: Expired due to Term

• Current Assignee: Remy Technologies LLC (BorgWarner Incorporated)
• Original Assignee: General Motors Corporation (General Motors Company)
• Inventors: Kirk, Thomas E., Anderson, Stephen W., Robinson, Melvin T., Steele, Roy B.
• Primary Examiner(s): Salce, Patrick R.
• Assistant Examiner(s): Hoff, Marc S.
• Application Number:
  US06/716,704
• Time in Patent Office: 503 Days
• Field of Search: 363/141, 363/144, 363/145, 310/68 D, 411/500, 411/525-528, 411/907, 411/908
• US Class Current: 363/145
• CPC Class Codes: H01L 2224/45147 Copper (Cu) as principal constituent
• CPC Class Codes: H01L 2224/48 of an individual wire connector
• CPC Class Codes: H01L 25/115 the devices being arranged next to each other
• CPC Class Codes: H01L 2924/00011 Not relevant to the scope of the group, the symbol of which is combined with the symbol of this group
• CPC Class Codes: H01L 2924/00014 the subject-matter covered by the group, the symbol of which is combined with the symbol of this group, being disclosed without further technical details
• CPC Class Codes: H02K 11/02 for suppression of electromagnetic interference
• CPC Class Codes: H02K 11/05 Rectifiers associated with casings, enclosures or brackets

Abstract

A bridge rectifier for a diode-rectified alternating current generator that is comprised of two metallic heat sinks formed respectively of copper and aluminum that are separated by an electrical insulator. Each heat sink carries a plurality of semiconductor diode chips. The diode chips are electrically connected to electrical connectors that are insert molded to insulator blocks that are supported by one of the heat sinks. The electrical connectors are adapted to be connected to the phase windings of an alternating current generator. The aluminum heat sink has a finned area which is adapted to be contacted by cooling air when the bridge rectifier is mounted in the generator.

Claims

1. A bridge rectifier for an alternating current generator comprising, a first metallic heat sink that is adapted to engage an end frame of an alternating current generator when the bridge rectifier is mounted to the generator, a second metallic heat sink, an electrical insulator sandwiched between said heat sinks for electrically insulating said heat sinks from each other, a first group of semiconductor diode chips supported by said first heat sink such that they are electrically connected to and in heat transfer relationship with said first heat sink, a second group of semiconductor diode chips supported by said second heat sink such that they are electrically connected to and in heat transfer relationship with said second heat sink, a plurality of insulator blocks supported by and secured to said second heat sink each carrying an electrical connector having a plurality of arms, each said electrical connector molded to a respective insulator block, each said insulator block having a dovetail-shaped portion that is disposed within a complementary dovetail-shaped slot formed in said second heat sink, said connectors being adapted to be connected to the phase windings of an alternating current generator, a pair of arms of each electrical connector being electrically connected to the respective faces of a pair of semiconductor diode chips where one of the pair of diode chips is a diode chip of said first group of diode chips and the other diode chip of the pair is a diode chip of the second group of diode chips, and a coating of insulating material covering each diode chip, said coating engaging and adhering to a connector arm and surface areas of said heat sinks adjacent each chip to encapsulate a diode chip.

2. A polyphase bridge rectifier adapted to be fixed to the end frame of an alternating current generator comprising, a first arcuately extending metallic heat sink that is adapted to be mounted in direct metal-to-metal contact with a surface of a metallic end frame of said generator, a second metallic heat sink secured to said first heat sink, a thin layer of electrical insulating material sandwiched between said heat sinks, said heat sinks being partially overlapped to provide a first surface on said first heat sink that is not covered by said second heat sink, said second heat sink having a finned portion that is not covered by said first heat sink that is adapted to be contacted by cooling air, said second heat sink having a second surface located adjacent said finned area that is axially spaced from said first surface of said first heat sink along an axis that is substantially normal to said first and second surfaces, a plurality of semiconductor diode chips each having one face thereof mounted on and connected respectively to said first and second axially spaced heat sink surfaces, said diodes being poled such that said heat sinks form direct voltage output terminals of opposite polarity, and a plurality of insulator blocks supported by said second heat sink overlapping said first surface of said first heat sink, each insulator block carrying an electrical connector that is adapted to be connected respectively to a phase winding of said generator, each electrical connector having a portion connected to faces of pairs of diodes mounted respectively on said first and second acially spaced heat sink surface, said layer of insulating material extending substantially coextensively with the overlapped surfaces of said heat sinks.

3. A polyphase bridge rectifier adapted to be fixed to the end frame of an alternating current generator comprising, a first metallic heat sink that is adapted to be mounted in direct metal-to-metal contact with a surface of a metallic end frame of said generator, a second metallic heat sink secured to said first heat sink, a thin layer of electrical insulating material sandwiched between said heat sinks, said heat sinks being partially overlapped to provide a first surface on said first heat sink that is not covered by said second heat sink, said second heat sink having a second surface that is axially spaced from said first surface of said first heat sink along an axis that is substantially normal to said first and second surfaces, a plurality of semiconductor diode chips each having one face thereof mounted on and connected respectively to said first and second axially spaced heat sink surfaces, said diodes being poled such that said heat sinks form direct voltage output terminals of opposite polarity, a plurality of insulator blocks supported by said second heat sink overlapping said first surface of said first heat sink, each insulator block carrying an electrical connector that is adapted to be connected respectively to a phase winding of said generator, each electrical connector having a portion connected to faces of pairs of diodes mounted respectively on said first and second axially spaced heat sink surface, said layer of insulating material extending substantially coextensively with the overlapped surfaces of said heat sinks, and a coating of insulating material covering each diode chip, said coating engaging and adhering to surface areas of said heat sinks adjacent each chip and portions of said electrical connectors that are connected to faces of said diode chips to thereby encapsulate a diode chip.

4. A polyphase bridge rectifier adapted to be fixed to the end frame of an alternating current generator comprising, a first arcuately extending heat sink that is formed of copper material that is adapted to be mounted in direct metal-to-metal contact with a surface of a metallic end frame of said generator, a second metallic heat sink formed of aluminum material secured to said first heat sink, a thin layer of electrical insulating material sandwiched between said heat sinks, said heat sinks being partially overlapped to provide a first surface on said first heat sink that is not covered by said second heat sink, said second heat sink having a finned portion that is not covered by said first heat sink that is adapted to be contacted by cooling air, said second heat sink having a second surface loated adjacent said finned area that is axially spaced from said first surface of said first heat sink along an axis that is substantially normal to said first and second surfaces, a plurality of semiconductor diode chips each having one face thereof mounted on and connected respectively to said first and second axially spaced heat sink surfaces, said diodes being poled such that said heat sinks form direct voltages output terminals of opposite polarity, a plurality of insulator blocks supported by said second heat sink overlapping said first surface of said first heat sink, each insulator block carrying an electrical connector that is adapted to be connected respectively to a phase winding of said generator, each electrical connector having a portion connected to faces of pairs of diodes mounted respectively on said first and second axially spaced heat sink surface, said layer of insulating material extending substantially coextensively with the overlapped surfaces of said heat sinks, and a coating of insulating material covering each diode chip, said coating engaging and adhering to surface areas of said heat sinks adjacent each chip and portions of said electrical connectors that are connected to faces of said chips to thereby encapsulate a diode chip.

5. A bridge rectifier for a diode-rectified alternating current generator comprising, a first metallic heat sink that is adapted to be mounted to a metallic end frame of said alternating current generator, a second metallic heat sink, means for electrically insulating said heat sinks from each other, first and second groups of diodes electrically connected respectively to said first and second heat sinks, said diodes being so poled that the heat sinks form positive and negative direct voltage output terminals, aligned openings in said heat sinks that are adapted to receive a metallic fastener for fastening the bridge rectifier to said end frame, insulating material carried by said second heat sink for electrically insulating said fastener from said second heat sink, and a metallic sleeve disposed within the opening in said second heat sink, said insulating material insulating said metallic sleeve from said second heat sink, said metallic sleeve engaging said metallic fastener and said first heat sink when said fastener is inserted into said sleeve to fasten said bridge rectifier to said end frame, said metallic sleeve ensuring an electrical connection between said metallic end frame and said first heat sink when said metallic fastener is inserted into said sleeve and said fastener is secured to said end frame.

6. A bridge rectifier adapted to be fixed to the end frame of an alternating current generator comprising, a first metallic heat sink that is adapted to be mounted in direct metal-to-metal contact with a surface of a metallic end frame of said generator, a second metallic heat sink secured to said first heat sink, means disposed between and in contact with said heat sinks for electrically insulating said heat sinks from each other, a plurality of diodes mounted on and electrically connected respectively to said first and second heat sinks, said diodes being poled such that said heat sinks form direct voltage output terminals of opposite polarity, and a plurality of insulator blocks supported by said second heat sink, each insulator block carrying an electrical connector that is adapted to be connected respectively to a phase winding of said generator, each electrical connector having portions electrically connecting pairs of diode mounted respectively on said first and second heat sinks, each insulator block having a dovetail-shaped portion that is disposed within a complementary dovetail-shaped slot formed in said second heat sink, said second heat sink having portions thereof staked into engagement with said insulator blocks for securing said insulator blocks to said second heat sink.