Compact rectifier bridge and method for manufacturing the same

Claim 2

A rectifier unit for an alternating current generator having a main axis associated therewith, said rectifier unit comprising: a first electrically conductive heat sink; a first diode electrically coupled to said first heat sink, said diode having an electrical lead; a second electrically conductive heat sink axially spaced from said first heat sink; a second diode electrically coupled to said second heat sink, said second diode having an electrical lead; and a diode terminal assembly sandwiched between said first and second heat sinks for electrically insulating said first and second heat sinks from each other, said diode terminal assembly having a lead terminal for electrically connecting leads from said first and second diodes, wherein said lead terminal is radially spaced from said first and second diodes.

Claim 3

The rectifier unit of claim 1 , wherein said first diode further comprises a first plurality of diodes, said second diode further comprises a second plurality of diodes, and said lead terminal further comprises a plurality of lead terminals.

Claim 4

The rectifier unit of claim 2 , wherein each lead terminal is in electrical connection with a terminal for a stator phase winding of an electric generator.

Claim 5

The rectifier unit of claim 2 , wherein each diode of said first plurality of diodes is diametrically opposed from a diode of said second plurality of diodes.

Claim 6

The rectifier unit of claim 4 , wherein each diode of said first plurality of diodes is angularly spaced from another.

Claim 7

The rectifier unit of claim 2 , wherein said first heat sink is arc shaped.

Claim 8

The rectifier unit of claim 2 wherein said first heat sink further comprises a first plurality of axially projecting spacers, said spacers for clampingly securing said sandwiched terminal assembly.

Claim 9

The rectifier unit of claim 7 wherein said second heat sink further comprises a second plurality of axially projecting spacers, said spacers for clampingly securing said sandwiched terminal assembly.

Claim 10

The rectifier unit of claim 2 , wherein said diode terminal assembly comprises a copper strap disposed within a plastic housing.

Claim 11

The rectifier unit of claim 2 , wherein said first heat sink further comprises a plurality of cooling windows and said second heat sink further comprises a plurality of radially extending cooling fins aligned with said plurality of cooling windows.

Claim 12

A rectifier unit for an alternating current generator having a main axis associated therewith, said rectifier unit comprising: a first electrically conductive heat sink, said first heat sink having an output terminal structure, said output terminal structure comprising a compressible tower disposed about an output terminal stud, and a cavity in the surface of said heat sink for receiving said output terminal stud, wherein the walls of said cavity rotationally secure said output terminal stud; a first diode electrically coupled to said first heat sink, said diode having an electrical lead; a second electrically conductive heat sink axially spaced from said first heat sink; a second diode electrically coupled to said second heat sink, said second diode having an electrical lead; and a diode terminal assembly sandwiched between said first and second heat sinks for electrically insulating said first and second heat sinks from each other, said diode terminal assembly having a lead terminal for electrically connecting leads from said first and second diodes, wherein said lead terminal is radially spaced from said first and second diodes.

Claim 13

A rectifier unit for an alternating current generator having a main axis associated therewith, said rectifier unit comprising: a first electrically conductive heat sink, said first heat sink having an output terminal structure, said output terminal structure comprising a compressible tower disposed about an output terminal stud, and a cavity in the surface of said heat sink for receiving said output terminal stud, wherein the walls of said cavity rotationally secure said output terminal stud; a first diode electrically coupled to said first heat sink, said diode having an electrical lead; a second electrically conductive heat sink axially spaced from said first heat sink; a second diode electrically coupled to said second heat sink, said second diode having an electrical lead; and a diode terminal assembly sandwiched between said first and second heat sinks for electrically insulating said first and second heat sinks from each other, said diode terminal assembly having a lead terminal for electrically connecting leads from said first and second diodes, wherein said lead terminal is radially spaced from said first and second diodes.

Claim 14

The rectifier unit of claim 11 , wherein said tower comprises a cast tower.

Claim 15

The rectifier unit of claim 11 , wherein said first diode further comprises a plurality of diodes, said second diode further comprises a plurality of diodes, and said lead terminal further comprises a plurality of lead terminals.

Claim 16

The rectifier unit of claim 13 , wherein each lead terminal is in electrical connection with a terminal for a stator phase winding of an electric generator.

Claim 17

The rectifier unit of claim 13 , wherein each diode of said first plurality of diodes is diametrically opposed from a diode of said second plurality of diodes.

Claim 18

The rectifier unit of claim 15 , wherein each diode of said first plurality of diodes is angularly spaced from another.

Claim 19

The rectifier unit of claim 13 wherein said first heat sink further comprises a first plurality of axially projecting spacers, said spacers for clampingly securing said sandwiched terminal assembly.

Claim 20

The rectifier unit of claim 17 wherein said second heat sink further comprises a second plurality of axially projecting spacers, said spacers for clampingly securing said sandwiched terminal assembly.

Claim 21

The rectifier unit of claim 13 , wherein said first and second heat sinks are arc shaped.

Claim 22

The rectifier unit of claim 13 , wherein said diode terminal assembly comprises a copper strap disposed within a plastic housing.

Claim 25

The method according to claim 21 , wherein said diode terminal assembly comprises an electrically conductive strap disposed with a plastic housing, and wherein the step of electrically coupling said leads comprise welding the leads of said first and second diodes to said strap.

Claim 26

The method according to claim 22 , wherein said leads radially extend to said strap.

Claim 27

The method of claim 21 , further comprising the step of providing a cavity within said first heat sink, providing a compressible output terminal tower on said first heat sink, disposing one end of an output terminal in said cavity and disposing a portion of said output terminal within said tower.