MXPA99002280A - Block of rectifier bridges that have improved dispersant heat characteristics and the free design of arcos electri training - Google Patents

Abstract

A block of rectifier bridges for use with an automotive alternator includes a base plate mounted conductively to a ground and which provides a negative heat dissipation, and a superimposed positive heat dissipating fin shaped structure having a surface area at least double the base plate, which is adjacent to the base plate to cooperatively define a camera between them. When used in connection with an AC electric generator of the standard type of three phases, the three terminals of the stator connection is, provided each one includes an upper portion which extends through the positive dissipation structure in a non-conductive relationship, and a smaller portion placed within the chamber and supported therein by a thermoconductive, non-conductive epoxy resin of electricity. The three diodes placed inside the camera extend between the motherboard and respectively one of the respective terminals Stator connection ales. A section of the coupling line is formed with the positive heat dissipation structure to which a directed current is coupled. A wiring directed to the voltage regulator extends through the positive heat dissipation structure to one of the terminals selected for connection of the stat

Description

BLOCK OF RECTIFIERS BRIDGES THAT HAVE IMPROVED HEAT DISPERSANT CHARACTERISTICS AND THE FREE DESIGN OF THE FORMATION OF ARCOS ELECTRICAL BACKGROUND OF THE INVENTION This invention relates generally to rectifier bridge blocks used with, for example, an automotive alternator. More specifically, the present invention relates to rectifier bridge blocks that have redesigned heat sinks and which eliminate the use of a plug between the rectifier bridge block and the current output that causes a battery.

A block of rectification bridges, commonly called a rectifier, is one of the component parts of an alternator block that forms a portion of the electric charge system in a car. The basic objective of the charging system is to recharge the charge of a battery with electricity generated by the alternator. The REF .: 29697 electric current generated by the alternator is an alternating current (AC), while the electric current preserved in the battery is a direct current (DC). The alternating current must be converted to a direct current so that the battery can be charged. This conversion is called rectification, and is the specific function of a block of rectification bridges.

The alternator used in a typical car is an electric generator of alternating current (AC) of the type of three phases. The electricity generated by each phase must be rectified by a rectifier bridge. Each bridge rectifier consists of two diodes and thus, three rectifier bridges are required by an alternator. Therefore, a block of rectifier bridges consists of three rectifier bridges with six diodes. Three of the six diodes are connected to ground, and the other three diodes are connected to the DC output that charges the battery.

During the rectification process, tremendous amounts of heat are generated by converting alternating current (AC) into direct current (DC). The heat must dissipate as quickly and efficiently as possible, or the diodes can be ruined in a relatively short period of time. Therefore, the bridges are usually welded on heat sinks of good heat conducting materials. Usually a portion of the earth provides a negative heat sink, and some structure associated with the DC output that the battery charges provides a positive heat sink that is conductively and thermally isolated from the ground.

The rectifier bridge blocks are normally mounted as an integrated part of an alternator assembly. The electric current of the alternator output to the battery depends greatly on the capacity of the rectifier bridge block to rectify the alternating current to a direct current. However, the rectification ability of the rectifier bridge block with the diodes at a fixed energy level depends to a large extent on the ability to distribute heat from the heat sinks used. The rectifier cooler can operate and heat can be distributed more quickly from the rectifier bridge block. The rectifier also has long life and greater rectification capacity. Therefore, the capacity of the heat dissipater (s) must be a main objective in the design of the bridge block of rectifiers.

Most rectifier bridge blocks used in automobiles have two heat sinks, one for the negative side and one for the positive side. However, this is not always the case. For example, in the block of rectifier bridges used in the 2G alternators of the Ford Motor Company, all six diodes are soldered on only one heat sink within an area no larger than 3.6 square inches. This particular design, which is common in the industry, tends to have very little capacity to distribute the heat. Nevertheless, the small heat dissipation area, the main output current are connected with a female plug and a male plug and both are constructed of a protective plastic. The electric arc occurs between the terminals of the female plug and the male plug due to constant vibration while the alternator is working. The low heat distribution capacity of these rectifiers makes these fail much more easily and prematurely, and the electric arc inherent in the female plug and male plug projects burns or corrodes the terminals of the connection.

Accordingly, there is a need for a block of novel rectifier bridges which overcomes the problems set forth above in the prior art designs by using two separate heat sinks and by eliminating the use of the male and female plug connections to make the Free design of electric arc formation. A block of novel rectification bridges must be adapted for use with standard alternator assemblies and have a design that. it can be manufactured at an affective cost. The present invention satisfies these needs and provides other related advantages.

BRIEF SUMMARY OF THE INVENTION The present invention resides in an improved rectifier bridge block having the improved ability to distribute heat and a free design of the formation of "electric arcs." The assembly generally comprises a base plate conductively mounted to a ground and which provides a negative heat sink, and a positive heat dissipating structure that extends in the form of a fin which abuts the base plate to cooperatively define a chamber between them.At least one stator connection terminal having an upper portion is provided. which extends through the positive heat dissipation structure in a non-conductive relation, and a small portion placed inside the chamber.The first diodes are placed 'between the base plate and at least one terminal of the stator connection, and the second diodes are placed between at least one terminal of the stator connection and the heat dissipating structure positive that covers.

In a preferred form of the invention, a block of rectification bridges are exposed for use with a car alternator. In this mode, the base plate is mounted to an alternator which serves as the ground for the block. To improve the heat distribution characteristics of the block, the positive heat dissipating structure is constructed so that it has a surface area that is at least twice the base plate. This is achieved, in part, by providing the structure in the form of a heat distributing fin.

In addition, means are provided for connecting the base plate to the extended positive heat dissipating structure in a non-electrical conductive relationship. The connection means comprise an insulating seal which is placed between the upper surface of the base plate and the positive heat dissipation structure and the insulated connection bolts.

In the preferred embodiment, at least one stator connection terminal comprises three stator connection terminals each receiving alternating current from the alternator. The stator connection terminals are supported inside the chamber by means of an epoxy non-electrically conductive, thermally conductive resin. The first diodes comprise three diodes which are placed between the base plate and one of the three terminals of the stator connection. Similarly, the second diodes comprise three diodes which are placed between one of the stator connection terminals and the extended positive heat dissipation structure.

The means are provided by directly coupling an output current directed towards the positive heat dissipation structure. The coupling means comprises a coupling line section that is integrally formed with the positive heat dissipation structure in which the output current is coupled. Once the coupling is made, the shrinkage-insulating sleeve is placed near the connection between the main output stream and the coupling line section, and subsequently the heat acts to safely carry the output current over the cross section. coupling line. In addition, a main voltage regulating wire extending to a is provided. through the positive heat dissipation structure to one of the selected stator connection terminals.

Other features and advantages of the present invention will be apparent from the following more detailed description, taken in conjunction with the accompanying drawings which illustrate, by way of example, the principles of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS The accompanying drawings illustrate the invention. In these drawings: FIGURE 1 is a top, front and side perspective view of a block of rectifier bridges that synthesizes the invention; FIGURE 2 is an elevated section taken generally along line 2-2 of FIG. 1.

FIGURE 3 is an enlarged, fragmented elevated section of the area indicated by the number 3 in FIG. 2, which illustrates the use of an electrically insulated connecting bolt for coupling an extended fin-shaped structure of positive heat dissipation to an underlying base plate that provides a negative heat sink; FIGURE 4 is an elevated section taken generally along line 4-4 of FIG. 1; FIGURE 5 is an elevated front view of the rectifier bridge block of FIG. 1, when the main wiring of the battery and the voltage regulator cable have been removed; FIGURE 6 is an elevated view of the rectifier bridge block; FIGURE 7 is an electrical schematic of the rectifier bridge block of FIGS. 1-6.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT As shown in the drawings for illustrative purposes, the present invention with a block of improved rectifier bridges, generally designated in the accompanying drawings by reference number 10. The block of improved rectifier bridges 10 serves to rectifying the alternating current produced, for example, in an automobile alternator, to a direct current suitable for receiving and storing it inside a car battery. The electrical schematic of the rectifier bridge block 10 of the present invention as illustrated in FIG. 7 is identical to that of a standard rectifier. As shown, the electricity generated in the stator 12 of a car alternator is fed into one of the three stator connection terminals 14-18. A first group of diodes 20 is placed between a ground (-) 22 and respectively one of the stator connection terminals 14-18, and a second group of diodes 24 is placed between respectively one of the stator connection terminals 14- 18 and one output to the battery (+) 26.

In accordance with the present invention, and with reference to FIGS 1-6, the rectifier bridge block 10 comprises an aluminum or copper base plate 28 which is mounted directly to the alternator block, and which provides a negative heat sink for the block. A positive heat dissipation structure 30 extends over the base plate 28 and, with the base plate 28, cooperatively defines a chamber 32 therebetween. The positive heat dissipation structure 30 includes a base portion 34 abutting the base plate 28 in a non-conductive manner, and a fin-shaped portion 36 that is spaced from the base plate 28 by the base portion 34. A gasket insulator 38 is placed between the joining portion of the base plate 28 and the positive heat dissipation structure 30.

The base plate 28 and the positive heat dissipation structure 30 have six openings through it which is aligned with another. Four mounting openings 40 are provided in the corners of the rectifier bridge block 10 to facilitate assembly of the block 10 to an underlying structure such as a portion of the alternator of an automobile. In addition, a pair of connection openings 42 is provided to secure the base plate 28 to the positive heat dissipation structure 30. As illustrated in FIG. 3, the portion of the base plate of the connecting openings 42 are tapered in order to receive and output the head of a plastic bolt 44 which is inserted through the ascending base plate 28 through the aligned connecting openings. 42 and held in place by the pressure rings 46 is sufficient to secure the base plate 28 adjacent to the minor surface of the positive heat dissipation structure 30. As shown in FIG. 1, the insulating wrapping cores 48 are provided through the mounting openings 40 in order to maintain the non-conductive relationship of electricity between the base plate 28 and the positive heat dissipation structure 30.

The positive heat dissipation structure 30 of the rectifier bridge block 10 is aligned so that the surface area thereof is at least twice that of the base plate 28. This significantly improves the heat distributing capacity of the rectifier bridge block 10. in comparison with the apparatuses of the prior art. The positive heat dissipation structure 30 defines a passage 50 towards the chamber 32 defined between the positive heat dissipation structure and the base plate 28. The stator connection terminals 14, 16 and 18 are placed inside the chamber 32 and the passage 50. In particular, each of the stator connection terminals 14-18 includes an upper portion 52 extending through passage 50 in a non-conductive relationship with the positive heat dissipation structure 30, and a portion smaller 54 that is placed inside the chamber 32. The upper portion 52 of the stator connection terminals 14-18 each receives alternating current (AC) from the alternator. The rectification of the alternating current (AC) to a direct current (DC) is performed by providing a first diode 20 between the base plate 28 and the smaller portion 54 of each stator connection terminal 14-18, and by providing a second diode between the minor portion 54 of each stator connection terminal 14 and the superimposed positive heat dissipation structure 30. An electrical connection terminal between diodes 20 and 24 and the stator connection terminals 14-18, the base plate 28 and the superimposed positive heat dissipation structure 30 is made by any known means, and preferably by welding. In addition, the stator connection terminals are supported within the chamber 32 by filling the chamber with an electrically non-conducting, thermoconductive epoxy resin 56.

Since the rectified direct current (DC) is directly diverted to the positive heat dissipation structure 30, all the rest provides an adequate coupling between the positive dissipation structure 30 and the main output current 58 to the battery. Therefore, the positive heat dissipation structure 30 includes a coupling line section 60 which is integrally formed by the fin-shaped portion 36 of the positive heat dissipation structure 30. The coupling line section 60. it includes a central threaded opening 62. The main wiring of the battery 58 may be provided with a receiver connector with suitable coupling line section 64 in which the coupling line section 60 may be inserted. A screw 66 can be used to securely secure the connector, and thus directs the wiring of the battery 58, to the coupling line section 60. Once this connection is made, the shrinkage insulating housing 68 can be placed near the connector 64. and the head acts to secure the wires carrying the output current 58 at the location relative to the coupling line section 60.

As it is desirable to provide a lead wire 70 from one of the stator connection terminals 14-18 to a voltage regulator, an opening 72 is provided in the fin-shaped portion 36 of the positive heat sink structure 30. which can pass the cable that goes to the voltage regulator.

From the aforementioned it will be appreciated that the rectifier bridge block 10 of the present invention incorporates a design that has a higher heat dissipation capacity efficiently than previous rectifier designs. Furthermore, the design of the rectifier bridge block 10 of the present invention eliminates any male and female plug between the battery 58 and an associated structure, thus eliminating the problem of the electric arc.

Although a particular embodiment of the invention has been described in detail for purposes of illustration, various modifications can be made without departing from the scope and perspective of the invention. Accordingly, the invention is not limited, except by the appended claims.

It is noted that in relation to this date, the best method known to the applicant to carry out the aforementioned invention, is that which is clear from the present description of the invention.

Having described the invention as above, the content of the following is claimed as property.

Claims (17)

RE IVIND ICAC IONS

1. A block of rectifier bridges, characterized in that it comprises: a base plate conductively mounted to a ground and providing a negative heat sink; a positive heat dissipation structure in the form of a superimposed fin attached to the base plate to cooperatively define a chamber therebetween; at least one stator connection terminal including a top portion extending through the positive heat dissipation structure superimposed in a non-conductive relationship, and a minor portion positioned within the chamber; the first group of diodes placed between the base plate and at least one stator connection terminal; the second group of diodes placed between at least one stator connection terminal and the superimposed positive heat dissipation structure; Y a coupling line section formed integrally with the positive heat dissipation structure, by directly coupling an output current directed towards the positive heat dissipation structure.

2. The block of claim 1, characterized in that it includes the shrink sleeve placed near the connection between the outlet stream and the coupling line section.

3. The block of claim 1, characterized in that it includes means for supporting at least one terminal of the stator connection inside the chamber.

4. The block of claim 3, characterized in that the. support means comprise an epoxy thermoconductive, non-electrically conductive resin.

5. The block of claim 1, characterized in that at least one stator connection terminal comprises three stator connection terminals in which each one receives alternating current (AC) from the alternator, where the first group of diodes comprises three diodes each one is placed between the base plate and respectively one of the three stator connection terminals, and where the second group of diodes comprises three diodes each is placed between one of the stator connection terminals and the superimposed positive heat dissipation structure.

6. The block of claim 5, characterized in that they include a cable that goes towards the voltage regulator extending through the positive heat dissipation structure towards one of the terminals of connection of the selected stator.

7. The block of claim 1, characterized in that it includes the means for connecting the base plate with the heat dissipation structure superimposed in a non-electrically conductive relationship.

8. The block of claim 7, characterized in that the connection means comprise an insulation joint between the surfaces of the base plate and the positive heat dissipation structure, and the insulating connection bolts.

9. The block of claim 1, characterized in that the surface area of the positive heat dissipation structure is at least double the base plate.

10. A block of rectifier bridges for use with an automobile alternator, characterized in that it comprises: a base plate mounted to an alternator and providing a negative heat sink; a positive heat dissipation structure in the form of a superimposed fin attached to the base plate to cooperatively define a chamber therebetween, the surface area of the positive heat dissipation structure is at least double the base plate; at least one stator connection terminal including an upper portion extending through the positive heat dissipation structure superposed in a non-conductive relationship, and a smaller portion placed within the chamber, at least one connection terminal of the stator supported inside the chamber by means of a thermoconductive, non-electrically conducting epoxy resin; the first group of diodes placed between the base plate and at least one stator connection terminal; the second group of diodes placed between at least one connection terminal 'stator and the superimposed positive heat dissipation structure; Y a coupling line section formed integrally with the positive heat dissipation structure, by directly coupling the output current directed towards the positive heat dissipation structure; Y a wiring directed towards the voltage regulator which extends through the positive heat dissipation structure towards at least one stator connection terminal.

11. The block of claim 10, characterized in that they include the shrinkage insulating sleeve placed near the connection between the outlet stream directed towards the coupling line section.

12. The block of claim 10, characterized in that it includes means for connecting the base plate to the positive heat dissipation structure superimposed in an electrically non-conductive relationship, wherein the connection means comprise an insulating seal placed between the surfaces of the base plate and the structure of positive heat dissipation, and insulating connection bolts.

13. The block of rectifier bridges for use with an alternator of a car, characterized in that it comprises: a base plate mounted to an alternator and providing a negative heat sink; a positive heat dissipation structure in the form of a superimposed fin attached to the base plate to cooperatively define a chamber therebetween, the surface area of the positive heat dissipation structure is at least double the base plate; means for connecting the motherboard to the positive heat dissipation structure superimposed on a non-electrically conductive relationship; a plurality of stator connection terminals which receive alternating current (AC) from the alternator and include an upper portion extending through the positive heat dissipation structure superimposed in a non-conductive relationship, and a minor portion placed within the the chamber, where the stator connection terminals are supported inside the chamber by means of a thermoconductive, non-electrically conducting epoxy resin; a plurality of a first group of diodes placed between the base plate or a plurality of stator connection terminals; a plurality of a second group of diodes placed respectively between one of the stator connection terminals and the superimposed positive heat dissipation structure; Y means for directly coupling an output current directed towards the positive heat dissipation structure, which includes a coupling line section integrally formed with the positive heat dissipation structure where the output current is coupled.

14. The block of claim 13, characterized in that it includes the shrink sleeve positioned near the connection between the outlet stream and the coupling line section.

15. The block of claim 13, characterized in that it includes a wiring directed towards the voltage regulator that extends through the positive heat dissipation structure to one of the stator connection terminals.

16. The block of claim 13, characterized in that the connecting means comprise an insulating joint between the surfaces of the base plate and the positive heat dispersion structure, and the insulating connecting bolts.

17. A block of rectifier bridges for use with an alternator of a car, characterized in that it comprises: a base plate mounted to an alternator and provide a negative heat sink; a positive heat dissipation structure in the form of a superimposed fin attached to the base plate to cooperatively define a chamber therebetween, the surface area of the positive heat dissipation structure is at least double the base plate; means for connecting the base plate to the positive heat dissipation structure superimposed on a non-electrically conductive relationship, which includes an insulating seal placed between the surfaces of the base plate and the positive heat dissipation structure, and the connecting bolts insulators; at least one stator connection terminal which receives alternating current (AC) from the alternator and includes an upper portion extending through the positive heat dissipation structure superimposed in a non-conductive relationship, and a minor portion placed within the the chamber, at least one terminal of the stator connection are supported inside the chamber by means of a thermoconductive, non-electrically conducting epoxy resin; a first group of diodes placed between the base plate and at least one stator connection terminal; a second group of diodes placed between at least one stator connection terminal and the superimposed positive heat dissipation structure; means for coupling, comprised of the coupling line section formed integrally with the positive heat dissipation structure, for directly connecting an output current which is directed towards the positive heat dissipation structure; an insulating sleeve placed near the connection between the outlet and the coupling line section; Y a wiring that is directed to the voltage regulator that extends through the positive heat dissipation structure to at least one of the stator connection terminals. SUMMARY OF THE INVENTION A block of rectifier bridges for use with an automotive alternator includes a base plate mounted conductively to a ground and which provides a negative heat dissipation, and a superimposed positive heat dissipating fin shaped structure having a surface area at least twice the base plate, which is adjacent to the base plate to cooperatively define a camera between them. When used in connection with an AC electric generator of the standard three-phase type, the three stator connection terminals are each provided with an upper portion which extends through the positive dissipation structure in a non-conducting relationship , and a smaller portion placed inside the chamber and supported on it by a thermoconductive epoxy resin, non-conductive of electricity. The three diodes placed inside the chamber extend between the base plate and respectively one of the respective stator connection terminals. A section of the coupling line is formed with the positive heat dissipation structure to which a directed current is coupled. A wiring directed to the voltage regulator extends through the positive heat dissipation structure to one of the terminals selected for stator connection.