Rectifier assembly with heat sink

{
  "publication_number": "US4321664A",
  "country": "US",
  "kind": "A",
  "title": "Rectifier assembly with heat sink",
  "abstract": "Two U-shaped sheet metal members having legs through which the cooling air passes have bases onto which at least two of the load current carrying diodes are fastened, the connection between the diodes and the sheet metal members forming the heat sink being a highly heat conductive connection.",
  "claims": [
    "1. In a rectifier assembly for furnishing DC current at a positive and negative terminal in response to AC energization, said rectifier assembly comprising a plurality of first diodes (14a, 14b, 14c) each having a cathode connected to said positive terminal and an anode, a plurality of second diodes (15a, 15b, 15c) each having an anode connected to said negative terminal and a cathode, and means connecting said anodes of said first diodes and said cathodes of said second diodes in pairs: a heat sink comprising at least a first and second U-shaped sheet metal member (39, 40; 239, 240; 339, 340, 341) each of said U-shaped members having legs (39b, 40b; 239b, 240b; 339b, 340b) each of said legs having a plurality of slots (71), each of said U-shaped members further having a base; wherein each of said bases has at least two of said diodes fastened thereto so as to create high thermal conductivity between said diodes and said U-shaped members; wherein said first diodes are fastened to said first U-shaped member and said second diodes are fastened to said second U-shaped member; wherein said first and second U-shaped members, respectively, form a conducting member connecting said anodes and said cathodes, respectively, to each other; and wherein said first diodes and said second diodes extend from said bases of said U-shaped sheet metal members in a direction parallel to the direction of said legs of said U-shaped sheet metal members in a direction parallel to the direction of said legs of said U-shaped sheet metal members; further comprising a V-shaped body (146) having said bases of said U-shaped metal members fastened thereto, thereby maintaining said U-shaped sheet metal members in a predetermined position relative to each other.",
    "2. In a rectifier assembly for furnishing DC current at a positive and negative terminal in response to AC energization, said rectifier assembly comprising a plurality of first diodes (14a, 14b, 14c) each having a cathode connected to said positive terminal and an anode, a plurality of second diodes (15a, 15b, 15c) each having an anode connected to said negative terminal and a cathode, and means connecting said diodes in pairs: a heat sink comprising at least a first and second U-shaped sheet metal member (39, 40; 239, 240; 339, 340, 341) each of said U-shaped members having legs (29b, 40b; 239b, 240b; 339b, 340b, 341b) each of said legs having a plurality of slots (71), each of said U-shaped members further having a base; wherein each of said bases has at least two of said diodes fastened thereto so as to create high thermal conductivity between said diodes and said U-shaped members; wherein said first diodes are fastened to said first U-shaped member and said second diodes are fastened to said U-shaped member; wherein each of said first diodes has a massive metallic base constituting said cathode and each of said second diodes has a massive metallic base constituting said anode; wherein said first and second U-shaped members, respectively, form a conducting member connecting said anodes and said cathodes, respectively, to each other; wherein said legs of said first U-shaped member extend in a first predetermined direction from said base of said first U-shaped member and said legs of said second U-shaped member extend in a second predetermined direction from said base of said second U-shaped member; wherein said first diodes are fastened to said base of said first U-shaped member so that said first diodes extend in a direction opposite said first predetermined direction, and said second diodes are fastened to said base of said second U-shaped member so that said second diodes project from said base in a direction opposite said second predetermined direction; and further comprising a plastic body (46,246) fastened to said bases of said U-shaped members and having recesses for receiving said diodes.",
    "3. A rectifier assembly as set forth in claim 2, wherein said plastic body has a V-shaped form (54).",
    "4. A rectifier arrangement as set forth in claim 3, wherein said V-shaped plastic body has a first and second lateral surface (47, 48) extending in a direction perpendicular to said bases of said U-shaped members; wherein said anodes of said first diodes and said cathodes of said second diodes extend through said first lateral surface; further comprising means for electrically connecting each of said anodes to a respective one of said cathodes.",
    "5. A rectifier assembly as set forth in claim 4, wherein said means for connecting each of said anodes to a respective one of said cathodes comprises a plurality of metal strips (12 a, 12 b, 12 c) abutting said first lateral surface of said plastic body.",
    "6. A rectifier assembly as set forth in claim 5, wherein said metal strips have bores; and wherein said anodes of said first diodes and said cathodes of said second diodes pass through said bores and are soldered to said metal strips in the region of said bores.",
    "7. A rectifier assembly as set forth in claim 4, further comprising three field exciter diodes, each having a cathode and an anode; wherein said cathodes of said field exciter diodes are electrically connected to each other and each of said anodes of said field exciter diodes is connected to a respective one of said anodes of said first diodes; and wherein said plastic body has further recesses for receiving said field exciter diodes.",
    "8. A rectifier assembly as set forth in claim 7, wherein said metal strips have further bores; and wherein said anodes of said field exciter diodes pass through said further bores and are soldered to said metal strips in the region of said further bores.",
    "9. A rectifier assembly as set forth in claim 8, wherein said cathodes of said field exciter diodes pass through said second lateral surface of said V-shaped plastic body; further comprising means connecting the so-protruding cathodes of said field exciter diodes to each other electrically.",
    "10. A rectifier assembly as set forth in claim 9, wherein said means for electrically connecting said so-protruding cathodes of said field exciter diodes to each other comprises a metal strip (53) abutting said plastic body.",
    "11. A rectifier assembly as set forth in claim 10, wherein each of said strips connecting said cathodes of said field exciter diodes to each other has a plurality of bores for allowing said passage of said cathodes therethrough; and wherein said cathodes are soldered to said strips in the region of said bores.",
    "12. A rectifier assembly as set forth in claim 11, wherein said plastic body comprises a first and second V-shaped member (46a, 46b) fitted one into the other and abutting each other at a boundary surface; and wherein said anodes of said first diodes and said cathodes of said second diodes protrude through said first lateral surface of said plastic body at said boundary surface.",
    "13. A rectifier assembly as set forth in claim 2, wherein said plastic body (246) is a bar-shaped body arranged between said U-shaped sheet metal members.",
    "14. A rectifier assembly as set forth in claim 13, wherein said plastic member comprises a first and second bar-shaped member abutting at a boundary surface (270); wherein said anode (244) of said first diode and said cathodes (245) of said second diodes terminate at said boundary surface; and further comprising a plurality of electrical conductors (212a, 212b, 212c) extending along said boundary surface and connecting said anodes and cathodes in pairs.",
    "15. A rectifier assembly as set forth in claim 14, further comprising three field exciter diodes, each having a cathode connected to the cathode of the others of said field exciter diodes and an anode connected to one of said electrical conductors; wherein said field exciter diodes (16a, 16b, 16c) are arranged in said plastic body so that said anodes of said field exciter diodes terminate at said boundary surface of said first and second plastic members; and wherein said anodes of said field exciter diodes are connected to said electrical conductors at said boundary surface.",
    "16. A rectifier assembly as set forth in claim 15, wherein each of said field exciter diodes has an axis extending along said boundary surface of said two plastic members; and wherein said field exciter diodes and said electrodes of said field exciter diodes have an axially symmetrical shape.",
    "17. In a rectifier assembly for furnishing DC current at a positive and negative terminal in response to AC energization, said rectifier assembly comprising a plurality of first diodes (14a, 14b, 14c) each having a cathode connected to said positive terminal and an anode, a plurality of second diodes (15a, 15b, 15c) each having an anode connected to said negative terminal and a cathode, and means connecting said anodes of said first diodes and said cathodes of said second diodes in pairs: a heat sink comprising at least a first and second U-shaped sheet metal member (39, 40; 239, 240; 339, 340, 341) each of said U-shaped members having legs (39b, 40b; 239b, 240b; 339b, 340b, 341b) each of said legs having a plurality of slots (71), each of said U-shaped members further having a base; wherein each of said bases has at least two of said diodes fastened thereto so as to create high thermal conductivity between said diodes and said U-shaped members; wherein said first diodes are fastened to said first U-shaped member and said second diodes are fastened to said second U-shaped member; wherein each of said first diodes has a masssive metallic base constituting said cathode and each of said second diodes has a massive metallic base constituting said anode; wherein said first and second U-shaped members, respectively, form a conducting member connecting said anodes and said cathodes, respectively, to each other; wherein said first diodes and said second diodes extend from said bases of said U-shaped sheet metal members in a direction parallel to the direction of said legs of said U-shaped sheet metal members; further comprising a V-shaped plastic body (146) having said bases of said U-shaped metal members fastened thereto, thereby maintaining said U-shaped sheet metal members in a predetermined position relative to each other.",
    "18. A rectifier assembly as set forth in claim 17, further comprising a plurality of electrical conductors, each for connecting one of said anodes of said first diodes to a respective one of said cathodes of said second diodes, and a plurality of insulating guide members (607, 608, 609) for maintaining said electrical conductors in position between said legs of said U-shaped members.",
    "19. A rectifier assembly as set forth in claim 18, further comprising three exciter field diodes each having a cathode connected to the cathode of the others of said exciter field diodes and each having an anode connected to one of said electrical conductors; wherein said plastic body has a plane of symmetry (S--S); and wherein said field exciter diodes (16a, 16b, 16c) are arranged in said plastic body in or near said plane of symmetry.",
    "20. In a rectifier assembly for furnishing DC current at a positive and negative terminal in response to AC energization, said rectifier assembly comprising a plurality of first diodes (14a, 14b, 14c) each having a cathode connected to said positive terminal and an anode, a plurality of second diodes (15a, 15b, 15c) each having an anode connected to said negative terminal and a cathode, and means connecting said anodes of said first diodes and said cathodes of said second diodes in pairs: a heat sink comprising at least a first and second U-shaped sheet metal member (39, 40; 239, 240; 339, 340, 341) each of said U-shaped members having legs (39b, 40b; 239b, 240b; 339 b, 340 b, 341b) each of said legs having a plurality of slots (71), each of said U-shaped members further having a base; wherein each of said bases has at least two of said didoes fastened thereto so as to create high thermal conductivity between such diodes and said U-shaped members; further comprising a third U-shaped sheet metal member (341); wherein each of said anodes of said first diodes and each of said cathodes of said second didoes comprises a massive metallic base (FIG. 16); and wherein said first, second and third U-shaped metallic members constitute the electrical connection between the anode of said first diode and said cathode of said second diode mounted thereon.",
    "21. A rectifier assembly as set forth in claim 20, wherein each of said U-shaped metallic members has legs extending in a predetermined direction relative to the base thereof; wherein said diodes mounted on said metallic members extend in a direction opposite said predetermined direction; further comprising a substantially U-shaped plastic body fastened to said bases of said U-shaped sheet metal members and having recesses for receiving said diodes.",
    "22. A rectifier assembly as set forth in claim 21, further comprising a first and second electrical conductor (380, 381) for, respectively, connecting said cathodes of said first diodes and said anodes of said second diodes to each other; wherein said plastic body has a top surface; and wherein said first and second conductors are flushmounted along said top surface.",
    "23. A rectifier assembly as set forth in claim 22, further comprising a first, second and third field exciter diode, each having a cathode connected to the other of said cathodes of said field exciter diodes and an anode connected to a respective one of said bases of said U-shaped metal members; wherein said plastic body has additional recesses for receiving said field exciter diodes, each of said additional recesses being interposed between one of said first and one of said second diodes, said U-shaped plastic body having an inner edge; further comprising a third electrical conductor (382) extending along said inner edge and interconnecting said cathodes of said field exciter diodes with each other.",
    "24. In a rectifier assembly for furnishing DC current at a positive and negative terminal in response to AC energization, said rectifier assembly comprising a plurality of first diodes (14a, 14b, 14c) each having a cathode connected to said positive terminal and an anode, a plurality of second diodes (15a, 15b, 15c) each having an anode connected to said negative terminal and a cathode, and means connecting said diodes in pairs: a heat sink comprising at least a first and second U-shaped sheet metal member (39, 40; 239, 240; 339, 340, 341) each of said U-shaped members having legs (29b, 40b; 230b, 240b; 339b, 340b, 341b) each of said legs having a plurality of slots (71), each of said U-shaped members further having a base; wherein each of said bases has at least two of said diodes fastened thereto so as to create high thermal conductivity between said diodes and said U-shaped members; wherein said first diodes are fastened to said first U-shaped member and second diodes are fastened to said U-shaped member; wherein said first and second U-shaped members, respectively, form a conducting member connecting said anodes and said cathodes, respectively, to each other; wherein said legs of said first U-shaped member extend in a first predetermined direction from said base of said first Us-ahped member and said legs of said second U-shaped member extend in a second predetermined direction from said base of said second U-shaped member; wherein said first diodes are fastened to said base of said first U-shaped member so that said first diodes extend in a direction opposite said first predetermined direction, and said second diodes are fastened to said base of said second U-shaped member so that said second diodes project from said base in a direction opposite said second predetermined direction; and further comprising a plastic body (46, 246) fastened to said bases of said U-shaped members and having recesses for receiving said diodes."
  ],
  "description_excerpt": "The present invention relates to rectifier assemblies for alternators, and, in particular, to alternators used in motor vehicles.\n\nIn a rectifier assembly disclosed in British Pat. No. 976,458, the diodes carrying the load current are arranged in pairs between two rails which are braced against each other and which also constitute electrical conductors. The electrical connection between the diodes and the rails is achieved by contact pressure. This arrangement has the disadvantage that two main diodes must be arranged one after the other in the axial direction of the alternator, so that a great deal of space is required. The cooling of these diodes is also difficult.\n\nIt is an object of the present invention to decrease the space required for the rectifier assembly in the axial direction of the generator. It is a further object of the present invention to furnish a heat sink whereby the cooling of the diodes is improved in spite of the lesser space occupied. This improved cooling improves the reliability of the assembly by decreasing the temperature at the depletion layer of the diodes for the same load current. Alternatively, if the temperature at the depletion layer is maintained the same as in conventional arrangements, the load current may be increased thereby increasing the possible range of application of the diode assembly.\n\nIt is a further object of the present invention to furnish a diode assembly which is relatively immune to vibration.",
  "cpc": [
    "H10W 90/00",
    "H02K 11/05",
    "H10W 40/43"
  ],
  "ipc": [
    "H01L 25/10",
    "H02K 11/04",
    "H02K 5/22",
    "H02K 9/22",
    "H10W 40/43"
  ],
  "assignees": [
    "Robert Bosch GmbH"
  ],
  "inventors": [
    "Gunter Matthai"
  ],
  "filing_date": "1980-01-14",
  "publication_date": "1982-03-23",
  "grant_date": "1982-03-23",
  "priority_date": "1979-02-07",
  "application_number": "US-11182280-A",
  "family_id": "6062327",
  "cited_by_count": 32,
  "citations": [
    "US3198972A",
    "US3187812A",
    "US3553505A",
    "US3970881A"
  ]
}