High performance bridge rectifier for diode-rectified alternating current generator

The present invention generally relates to bridge rectifiers for rectifying the current output of an alternating current generator. More specifically, the present invention relates to a high performance bridge rectifier which utilizes an improved first heat sink, an improved carrier plate second heat sink, an improved connection cover of the rectifier, improved first polarity and second polarity diodes, improved diode layout over the first and the second heat sinks, improved diode contact with the electrical contacts of the rectifier, and said rectifier is especially characterized by an improved B stud that more efficiently dissipates heat to properly cool the rectifier while providing current to various electrical loads such as, for example, a motor.

Bridge rectifiers are used to rectify current output from alternative current sources, such as an alternating current generator. Bridge rectifiers for motor vehicle alternators are well known in the art and generally include two metal parts used as heat sinks that are electrically insulated from each other. As a result of the current that is transmitted therethrough, the bridge rectifier becomes heated due to the internal power loss on each individual diode. Thus, the bridge rectifier must be properly cooled in order to be able to handle the maximum required current, while still being tolerant to increased temperatures due to internal power losses.

Each of the metal parts or carrier plates includes semiconductor diodes that are arranged to polarize the two metal parts into respective positive and negative direct voltage output terminals. The diodes are then connected to respective phase windings of an output winding of the alternating current generator.

The rectifier diodes are connected to respective carrier plates, and these carrier plates are used as heat sinks for these diodes as well. The rectifier diodes are typically inserted by pressure in receiving bore holes of the carrier plate or heat sink, or are soldered to the carrier plate using appropriate solder alloys. The end wires connected to the rectifier diodes enable the rectifier diodes to be connected to external sources.

Various difficulties or problems have occurred using this standard diode rectifier. For example, since the diode rectifier is mounted to an alternating current generator that is used with a motor, there are space limitations within the motor, for example, which limit the size of the diode rectifier. One prior art solution to this problem is constructing or fabricating the carrier plates that are connected to the rectifier diodes into a shape that is more than a half circle approximating the circular shape of the alternating current generator. The carrier plates are constructed as a positive heat sink and a negative heat sink and the two heat sinks are arranged coaxially in separate planes spaced apart by an axial distance from one another. See, for example, U.S. Pat. No. 4,952,829 to Armbruster, et al., incorporated herein by reference.

Another problem experienced with diode rectifiers includes the need to carefully match the diode characteristics in order to avoid imbalance in the amount of current conducted by the individual diodes. If thermal imbalance is experienced, certain diodes will increase current flow that may result in thermal runaway. Thermal runaway involves a diode that is unable to regulate its current flow and temperature. In this situation, the diode conducts increased current and experiences increased temperature until the individual diode is no longer able to sustain the normal working reverse voltage, and the diode is destroyed. Frequently, thermal runaway results in the destruction of an individual diode, and the destroyed diode becomes short-circuited thereby rendering the entire bridge rectifier inoperative.

It is another object of embodiments of the present invention to provide an increased current and heat capacity bridge rectifier which includes a first (negative) heat sink with maximized conduction surface area, in direct contact with the alternator top cover–the slip-ring-end, allowing increased heat transfer from the negative diodes and from the second (positive) heat sink, through the electrically insulating, but thermally conductive separator foil.

It is yet another object of embodiments of the present invention to provide an increased current and heat capacity bridge rectifier which includes a first (negative) heat sink with optimal thickness, allowing a lower thermal impedance to the heat transfer from the second (positive) heat sink, through conduction, to the alternator slip-ring-end body, offering at the same time reduced production costs. The thickness of this heat sink has been harmonized with the negative diode design, so that maximum heat conduction is possible.

It is still another object of embodiments of the present invention to provide an increased current and heat capacity bridge rectifier which includes a first (negative) heat sink having a new diode layout, for better balancing heat loads on the rectifier, and a lower maximum working temperature.

It is a further object of embodiments of the present invention to provide an increased current and heat capacity bridge rectifier which includes a second (positive) heat sink or carrier plate, having a base section area, increased in height, thereby increasing the volume of the carrier plate to increase the current and thermal characteristics, also the convection surface area. While it is difficult to increase the surface area of the carrier plate in the radial direction, i.e., in the same plane as the carrier plate, it is nevertheless possible to increase the depth or height of the forced-cooling fin-section in the carrier plate and the base section to be coextensive with the cover of the carrier plate, since this additional space had not been previously utilized.

It is yet a further object of embodiments of the present invention to provide an increased current and heat capacity bridge rectifier which includes a second (positive) heat sink or carrier plate, having maximized base contact surface area for optimized conduction to the thermally conductive foil and the first heat sink.

It is still a further object of embodiments of the present invention to provide an increased current and heat capacity bridge rectifier which includes a second (positive) heat sink or carrier plate, having deep grooves on the top face of the base section, offering considerably increased convection area to further cool the rectifier said heat sink. These grooves connect to the vertical radial slots in the base section and plateau section of the heat sink, thus expanding the area of the second heat sink included in the forced convection process, greatly increasing cooling performance.

It is yet still another object of embodiments of the present invention to provide an increased current and heat capacity bridge rectifier which includes a second (positive) heat sink or carrier plate, having a plateau section area with increased height thus enabling a large surface area used for forced convection and better cooled first heat sink and diodes.

It is yet still a further object of embodiments of the present invention to provide an increased current and heat capacity bridge rectifier which includes a second (positive) heat sink or carrier plate, having optimized diode layout for balanced thermal load distribution over the whole heat sink.

It is still another object of embodiments of the present invention to provide an increased current and heat capacity bridge rectifier which includes a second (positive) heat sink or carrier plate, having cylindrical counter bore slots with dome shaped ceilings to accommodate the negative diodes of the first (positive) heat sink, without impeding on the convection surface area of said heat sink carrier plate base section.

It is still yet another object of embodiments of the present invention to provide an increased current and heat capacity bridge rectifier which includes a connection cover, having a bottom area at a certain small distance with respect to the top face of the carrier plate base section, this bottom face having filleted radial edges on the inside and the outside. These fillets and distance allow the low pressure created by the alternator fan in the vertical radial slots to suck in air over the top of the carrier plate base section, and through the grooves, creating a new area cooled by forced convection in the rectifier.

About the Author

Founded in 1989,ZENLI RECTIFIER CO.,LTD specialty in design,research,manufacture,sale of power semiconductor,Company sit at “China-Electrics-City”-LiuShi, Wenzhou, Land area 5000m2, building area 3500m2, . Major product: Diode, Thyristor, Bridge Rectifier, Power Modules, Solid State Relay, Semiconductor Subassembly and so on.

Crazy Bridge Base Jumps HD

KitchenAid Hard-Base Porcelain Aluminum Nonstick 18-by-10-Inch Two-Burner Griddle, Red $62.00 Extends over the depth of two stove top burns providing ample cooking surface. Cool grip handles – 18/10 stainless steel shaft encased in soft silicone rubber provide a soft cool, confident grip. Three-coat nonstick surface includes patented ”Hard-Base” ceramic primer that hardens the inside of the pan providing exceptional food release and durability. Heavy gauge aluminum core guarantees fas…

Round Pedestal Dining Table – Table Only (Cottage Oak) (30H x 42W x 42D) $330.00 This beautifully designed Round Pedestal Dining Table is perfect for any home decor. For dinner or family get-togethers, it’s classic design can’t be topped. The solid wood material is finished in a sophisticated Cottage Oak that will give your home a classic and refined feel! Table Only. Assembly level/degree of difficulty: Moderate….

Jos Fauxtographee Abstract – The metal base of a bridge done four ways on a red mountain landscape – Mugs The metal base of a bridge done four ways on a red mountain landscape Mug is new. Why drink coffee out of an ordinary mug when an imprinted mug is so much cooler? Microwave safe, FDA approved. Image is printed on both sides of the mug. Dishwasher use is not recommended….

Sign $7.99 12 tracks. CRC version – Tiny scuff on disc will not affect play. ARCD 8740…

Ace Of Base – Greatest Hits $7.99 ACE OF BASE GREATEST HITS…

Bridge $1.60 15 tracks. CRC version? -…

Hunter 23963 Stockbridge 70-Inch 3-Speed Ceiling Fan with 5 Walnut/Medium-Oak Blades and Light Fixture, New Bronze $189.72 With its powerful whisperwind motor and large blade size and design, this fan is perfect for large indoor rooms….

Deckorators 81060 Solar Tiffany Style Sunflower Post Cap with Cedar Base $32.73 Solar LED Tiffany Style – “Sunflower” Post Caps – 4″ x 4″ Light up your bridge day and night with our Solar LED Post Caps. By day, these post caps add a charming touch to your bridge, porch, fence, or any outdoor area. By night, they enhance your bridge with lovely accent lighting-without the hassles of wiring or electricity! Add the beauty of Tiffany-style stained glass to any outdoor area Enhanc…

Gotham Tiffany Style Downbridge Desk Lamp $179.99 This downbridge desk lamp has lovely Tiffany-style glass. Features an adjustable arm on a sturdy square base in an antique bronze finish. By Quoizel….

The Presidio $3.84 Sean Connery is a veteran Army M.P. officer, Mark Harmon an ex-soldier turned police detective. Together these unwilling allies must investigate a murder at San Francisco’s famed military base, and while doing so uncover a dangerous smuggling scheme. Taut thriller also stars Meg Ryan. 96 min. Widescreen; Soundtracks: English Dolby Digital 5.1, Dolby Digital Surround, French Dolby Digital Surround;…

BRIDGE,48X24,MY/CCL $433 38000 Series Bridge, 48w x 24d x 29-1/2h, Mahogany Top/Charcoal Base

BRIDGE,CURVED BASE,CY $657 Napoli Series Right-Hand Veneer Bridge, 48w x 24d x 29½h, Sierra Cherry

Dragon Optical GG Sunglasses – Color Injected (For Men and Women) $106.5 CLOSEOUTS . Dragon Optical’s GG sunglasses kick up the style with a retro frame and wide lenses for full coverage protection. Carry case doubles as lens cloth Lenses: 8-Base lens curvature for distortion-free vision 100% UV protection Material: Polycarbonate 60mm width Frame: Lightweight and durable Metal accent across bridge to temples Material: Grilamid(R) 5-1_4" temple to temple Made in Italy. Visit our Sunglasses Buying Guide Available Colors: JET MATTE STRIPE/BRONZE, RED IVORY SPLIT/BRONZE GRADIENT, NEAPOLITAN/GRADIENT ROSE, SEA SPLIT/GREY IONIZED, HAMPTONS BLUE/GREY GRADIENT, SEA FADE/PURPLE IONIZED, TRANSLUCENT SKY/GREY GRADIENT.

HON(R) 38000 Bridge For Desks/Credenzas, 29 1/2in.H x 42in.W x 24in.D, Light Gray $411 Durable pieces combine to create an efficient workspace. Solidly constructed of steel-over-honeycomb laminate tops, the HON 38000 Modular collection provides rigidity and strength, yet remains light and easy to configure and reconfigure. The Light Gray steel base and laminate tops exude a professional look that is easy to maintain. Meets or exceeds ANSI/BIFMA and ISTA performance standards – pieces have met quality standards for safety and durability established by the American National Standards Institute (ANSI) and the Business and Institutional Furniture Manufacturers Association (BIFMA). Easy assembly instructions included. Each piece is sold individually. Cord management keeps your desktop free of wires. Features management ports and tracks that run through hidden channels for a neat, organized work environment.

HON(R) 38000 Bridge For Desks/Credenzas, 29 1/2in.H x 48in.W x 24in.D, Light Gray $433 Durable pieces combine to create an efficient workspace. Solidly constructed of steel-over-honeycomb laminate tops, the HON 38000 Modular collection provides rigidity and strength, yet remains light and easy to configure and reconfigure. The Light Gray steel base and laminate tops exude a professional look that is easy to maintain. Meets or exceeds ANSI/BIFMA and ISTA performance standards – pieces have met quality standards for safety and durability established by the American National Standards Institute (ANSI) and the Business and Institutional Furniture Manufacturers Association (BIFMA). Easy assembly instructions included. Each piece is sold individually. Cord management keeps your desktop free of wires. Features management ports and tracks that run through hidden channels for a neat, organized work environment.

HON(R) 38000 Credenza Shell, 29 1/2in.H x 65 1/2in.W x 28in.D, Light Gray $772 Durable pieces combine to create an efficient workspace. Solidly constructed of steel-over-honeycomb laminate tops, the HON 38000 Modular collection provides rigidity and strength, yet remains light and easy to configure and reconfigure. The Light Gray steel base and laminate tops exude a professional look that is easy to maintain. Meets or exceeds ANSI/BIFMA and ISTA performance standards – pieces have met quality standards for safety and durability established by the American National Standards Institute (ANSI) and the Business and Institutional Furniture Manufacturers Association (BIFMA). Easy assembly instructions included. Each piece is sold individually. Cord management keeps your desktop free of wires. Features management ports and tracks that run through hidden channels for a neat, organized work environment. Offers additional working room. Use the credenza alone or combine with the desk shell and bridge to create an U-shaped configuration.

HON(R) 38000 Modular 72in.W Credenza Shell, 29 1/2in.H x 72in.W x 24in.D, Gray Patterned/Light Gray $851 Durable pieces combine to create an efficient workspace. Solidly constructed of steel-over-honeycomb laminate tops, the HON 38000 Modular collection provides rigidity and strength, yet remains light and easy to configure and reconfigure. The Light Gray steel base and laminate tops exude a professional look that is easy to maintain. Meets or exceeds ANSI/BIFMA and ISTA performance standards – pieces have met quality standards for safety and durability established by the American National Standards Institute (ANSI) and the Business and Institutional Furniture Manufacturers Association (BIFMA). Easy assembly instructions included. Each piece is sold individually. Cord management keeps your desktop free of wires. Features management ports and tracks that run through hidden channels for a neat, organized work environment. Offers additional working room. Use the credenza alone or combine with the desk shell and bridge to create an U-shaped configuration. Plenty of space for answering machines, printers or other equipment. SCS Indoor Advantage Certified for healthier indoor air quality. Manufactured with reduced harsh chemicals and with processes that are ‘low VOC’ (low in Volatile Organic Compounds). Level 2 certified as sustainable based on multiple environmental and/or social attributes.

HON(R) 38000 Modular 72in.W Credenza Shell, 29 1/2in.H x 72in.W x 24in.D, Light Gray $851 Durable pieces combine to create an efficient workspace. Solidly constructed of steel-over-honeycomb laminate tops, the HON 38000 Modular collection provides rigidity and strength, yet remains light and easy to configure and reconfigure. The Light Gray steel base and laminate tops exude a professional look that is easy to maintain. Meets or exceeds ANSI/BIFMA and ISTA performance standards – pieces have met quality standards for safety and durability established by the American National Standards Institute (ANSI) and the Business and Institutional Furniture Manufacturers Association (BIFMA). Easy assembly instructions included. Each piece is sold individually. Cord management keeps your desktop free of wires. Features management ports and tracks that run through hidden channels for a neat, organized work environment. Offers additional working room. Use the credenza alone or combine with the desk shell and bridge to create an U-shaped configuration. Plenty of space for answering machines, printers or other equipment.

HON(R) 38000 Modular 72in.W Credenza Shell, 29 1/2in.H x 72in.W x 24in.D, Mahogany/Charcoal $851 Durable pieces combine to create an efficient workspace. Solidly constructed of steel-over-honeycomb laminate tops, the HON 38000 Modular collection provides rigidity and strength, yet remains light and easy to configure and reconfigure. The charcoal steel base and Mahogany-finished laminate tops exude a professional look that is easy to maintain. Meets or exceeds ANSI/BIFMA and ISTA performance standards – pieces have met quality standards for safety and durability established by the American National Standards Institute (ANSI) and the Business and Institutional Furniture Manufacturers Association (BIFMA). Easy assembly instructions included. Each piece is sold individually. Cord management keeps your desktop free of wires. Features management ports and tracks that run through hidden channels for a neat, organized work environment. Offers additional working room. Use the credenza alone or combine with the desk shell and bridge to create an U-shaped configuration. Plenty of space for answering machines, printers or other equipment. SCS Indoor Advantage Certified for healthier indoor air quality. Manufactured with reduced harsh chemicals and with processes that are ‘low VOC’ (low in Volatile Organic Compounds). Level 2 certified as sustainable based on multiple environmental and/or social attributes.

HON(R) 38000 Modular Credenza Shell, 29 1/2in.H x 65 1/2in.W x 28in.D, Gray Patterned/Light Gray $772 Durable pieces combine to create an efficient workspace. Solidly constructed of steel-over-honeycomb laminate tops, the HON 38000 Modular collection provides rigidity and strength, yet remains light and easy to configure and reconfigure. The Light Gray steel base and laminate tops exude a professional look that is easy to maintain. Meets or exceeds ANSI/BIFMA and ISTA performance standards – pieces have met quality standards for safety and durability established by the American National Standards Institute (ANSI) and the Business and Institutional Furniture Manufacturers Association (BIFMA). Easy assembly instructions included. Each piece is sold individually. Cord management keeps your desktop free of wires. Features management ports and tracks that run through hidden channels for a neat, organized work environment. Offers additional working room. Use the credenza alone or combine with the desk shell and bridge to create an U-shaped configuration. Plenty of space for answering machines, printers or other equipment. SCS Indoor Advantage Certified for healthier indoor air quality. Manufactured with reduced harsh chemicals and with processes that are ‘low VOC’ (low in Volatile Organic Compounds). Level 2 certified as sustainable based on multiple environmental and/or social attributes.