Rectifier unit for provision in an alternator

Claim 2

Rectifier unit for a 3-phase alternator having three formed metal cooling plates each connected to a different one of the alternating current terminals of said alternator, on which plates diodes are mounted and to which the diodes mounted thereon have one of their terminals connected, and also an insulating plate on which conductor paths for connecting up the diodes are provided and including the improvement, according to the invention, wherein: there are thermally and electrically connected to each said cooling plate, one exciter field circuit diode, at least one positive side diode and at least one negative side diode, and each of said cooling plates (26,27,28) has the form of a circular sector disk with a claw-like extension at right angles thereto at its outer edge.

Claim 3

Rectifier unit as defined in claim 1, in which there are thermally and electrically connected to each said cooling plate (26,27,28) one pair of positive side diodes (15,17;18,19;20,21), one pair of negative side diodes (10,11;12,13;14,15) and one exciter field circuit diode (22,23,24).

Claim 4

Rectifier unit as defined in claim 1, in which said insulating plate (36) is made of polyamide synthetic resin material and is shaped essentially in the form of a circular sector with a central aperture with various ridges, perforated bosses and the like thereon and each of said cooling plates (26,27,28) is riveted into a corresponding sector of said insulating plate (36).

Claim 5

Rectifier unit as defined in claim 3, in which said insulating plate (36) is provided with a plurality of pillar-like studs (68 to 73) each provided with a central bore and tapered at one end, and in which said pillar-like studs extend into corresponding bores in the cooling plates and terminate flush with the cooling plate surface on the far side of the respective bores, and in which rivets (29 to 35) extend through the bores of said pillar-like studs and are riveted over on insulating washers lying on the surface of the respective cooling bodies and lock washers (86) lying against the insulating plates surrounding the respective bores.

Claim 6

Rectifier unit as defined in claim 3, in which said insulating plate (36) has a raised circumferential rim (46) and has a central circular passage opening (99) and in which a collar-like prominence (42) is provided that surrounds said opening (99) for a major portion of its circumference in keyhole shape and defines, at the location at which it leads away from said central opening (99), an approximately rectangular surface of the insulating plate (36) which it accordingly encloses with said central opening, said collar-like prominence (42) at its edge farthest removed from the disk portion of said insulating plate being covered by a sealing member (74).

Claim 7

Rectifier unit as defined in claim 3, in which said insulating plate (36) has a plurality of wires (48,56,64) embedded therein, constituting the aforesaid conducting paths, and that these conducting wires are accessible in a multiplicity of bores (47,49 to 55, 57 to 63, 65 to 67) through said insulating plate, said conducting wires (48,56,64) being drawn out of a portion of said bores (50 to 55, 58 to 63, 65 to 67) in the form of loops for facilitating access thereto.

Claim 8

Rectifier unit as defined in claim 6, in which a leaf spring (44) is affixed by a stud (45) to said insulating plate (36) and that a foot portion of said leaf spring (44) lying against said insulating plate (36) has an elbowed extension that projects over a bore (47) in said insulating plate (36) and is there galvanically connected with one (64) of said conducting wires embedded in said insulating plate (36), said elbowed extension of the foot portion of said leaf spring (44) lying against a rib (43) formed in said insulating plate (36).

Claim 9

Rectifier unit as defined in claim 1, in which each of said positive-side diodes, said negative-side diodes and said exciter field circuit diodes (10 to 24) has a cylindrical casing provided with a bead near the end through which the diode connection leads (87), and in which the diodes are pressed into corresponding openings provided in the cooling plates (26,27,28) from the side on which the cooling plate is later applied and fastened with their respective beads against that side of the cooling plate.

Claim 10

Rectifier unit as defined in claim 8, in which the diode lead wires (87) extend through bores (50 to 55, 58 to 63, 65 to 67) in which there is in each case a loop of one of a plurality of wires embedded in said insulating plate (36), the diode lead and the wire loop in each bore being galvanically connected to each other.

Claim 11

Rectifier unit as defined in claim 1, in which each of said positive-side diodes, negative-side diodes and exciter field circuit diodes (10 to 24) is provided with a cylindrical housing having a flange or bead at its end opposite to the end through which the diode lead wire (87) is brought out, and in which the diodes are pressed into corresponding bores of the respective cooling plates (26 to 28) from the sides of the cooling plates opposite to that on which said conducting plate is fastened thereto, so that said flange or bead lies against that side of the respective cooling body.

Claim 12

Rectifier unit as defined in claim 1, in which a threaded stud (38) is provided having a first section (84) having threads provided thereon, a second section in the shape of a thickened cylindrical portion (95) and a third section (85) of relatively thinner cross-section, compared to the threaded section, and in which said threaded stud is insulated by an insulating disk (92), an insulating bushing (91) and a second insulating disk (90) and is fastened to one of said cooling plates without electrical connection thereto by a nut (83) on said threaded section bearing against the end of said thickened cylindrical section, and in which also said third section (85) of relatively thinner cross-section of said threaded stud (38) is surrounded by a hollow rivet (93) and fastened to said insulating plate (36) by deforming the stud end and the adjoining portion of the hollow rivet over an interposed washer (94), and said thickened cylindrical portion (95) of said threaded stud (38) is provided with a radial bore through which a wire (96) is led that extends to the location of a diode lead wire (87) and is galvanically connected both to said diode lead wire (87) and to a wire (64) embedded in said insulating plate (36) and providing a loop in a bore of said conducting plate through which said diode lead wire (87) projects.

Claim 13

Rectifier unit as defined in claim 11, in which a second threaded stud (37) is provided that has a first threaded section, a second cylindrically thickened section and a third section of relatively small diameter, and in which said threaded stud passes through and connects electrically one of said cooling plates other than the one in which said first threaded stud is inserted and is fastened thereto by a nut (82) on its threaded section bearing against said cylindrically thickened section of said stud, and in which also the portion of relatively smaller diameter of said second threaded stud (37) is surrounded by a hollow rivet and extends, along with said hollow rivet through a bore in said insulating plate (36) and is fastened to said insulating plate by deforming the end of said stud and that of said hollow rivet over an underlying washer bearing against said insulating plate, said second threaded stud being connected to an output terminal for providing alternator speed information.

Claim 14

Rectifier unit as defined in claim 12, in which a pair of connection studs having a groove in the end surface thereof, are provided mounted perpendicularly to said insulating plate (36) in bores (49,57) through said insulating plate and in said bores are galvanically connected with the beginning and end of substantially circular wires (48,56) embedded in said insulating plate, each of which are connected to the lead wires of a plurality of diodes, each of said connection studs being connected with one of the d.c. output terminals (5,6) of the rectifier unit.

Claim 15

Rectifier unit as defined in claim 1, in which one of said cooling plates is connected to an output terminal (9) for providing alternator speed information.