Rectifying apparatus including six semiconductor diodes sandwiched between ceramic wafers

Claim 1

A semiconductor full wave rectifier assembly for mounting in the alternator of an automobile including: a generally planar first lower ceramic base having two opposing major surfaces, a first metallization covering a portion of and being coextensive with one of said major surfaces and a second metallization covering a portion of the other of said major surfaces, the area of a major surface of said lower ceramic base being about 1.2 inches by about 1.625 inches thereby providing small size and low weight for the rectifier assembly; a second, third and fourth generally planar upper ceramic bases, each having two opposing major surfaces, the combined area of the major surfaces of said second, third and fourth ceramic bases being about equal to or less than the area of the major surfaces of said first lower ceramic base; a third, fourth and fifth metallization covering at least a portion of and being coextensive with one major surface of said second, third and fourth ceramic bases, respectfully, and each of said upper ceramic bases including an opening therethrough between said two major surfaces adapted to receive a lead extending therethrough for electrically coupling each of said third, fourth and fifth metallizations to the other side of said second, third and fourth ceramic bases, respectively; a first and second diode having opposing terminals connected to said third metallization so that forward current flow through said first and second diodes is in opposite directions with respect to said third metallization; a third and fourth diode having opposing terminals connected to said fourth metallization so that forward current flow through said third and fourth diodes is in opposite directions with respect to said fourth metallization; a fifth and sixth diode having opposing terminals connected to said fifth metallization so that forward current flow through said fifth and sixth diodes is in opposite directions with respect to said fifth metallization; said first, third and fifth diodes having terminals connected to said first metallization; said second, fourth and sixth diodes having terminals connected to said second metallization; said third, fourth and fifth metallizations each being adapted to be connected to one of the three output phase of the alternator; said first and second metallizations being adapted to provide a direct current output from said rectifier, said first metallization extending around an edge of said lower ceramic base and covering at least a portion of each of said two major surfaces, only one of said two opposing major surfaces being adjacent said diodes; said upper and lower ceramic base being fabricated substantially of beryllia and having a sufficiently high heat transfer capability to cool said diodes during rectifying operation by providing for transfer of heat from said diodes through both said upper and said lower ceramic bases; said metallization being molybdenum coated with copper so that the stress between the copper and the ceramic base due to thermal expansion is reduced; and said diodes being semiconductor wafers and being removable from said rectifier assembly without disturbing more than one other semiconductor wafer thus increasing yield by permitting a defective diode to be removed.