Abstract: A voltage regulator includes a voltage regulator body and connectors carried by the body, which connect to devices controlled by the voltage regulator. A substrate board is received in a board receiving cavity of the voltage regulator body and includes a metallic base layer, an insulator layer on the metallic base layer, and a circuit layer on the insulator layer and defining a printed circuit pattern. Active and passive voltage regulator components are mounted on the substrate board and interconnected by the printed circuit pattern to form a voltage regulating circuit. Terminal connections, such as conductive pins, are secured to the substrate board and operatively connected to selected active and passive components or printed circuit pattern and extend from the substrate board for interconnecting the connectors carried by the voltage regulator body.

Abstract: A voltage regulator controls voltage supplied from a generator or alternator and includes a voltage regulator body having at least one component receiving cavity. A lead frame is embedded within the voltage regulator body and forms external lead frame connectors and internal lead frame connectors. A voltage regulator integrated circuit and passive components are mounted within the at least one component receiving body and connected to the selected internal lead frame connectors. The lead frame can be configured such that one or more passive components are positioned over or under at least a portion of the voltage regulator IC.

Abstract: A powder coating gun with an internal fan and a quick-change powder cartridge. Pressurized air generated by the fan entrains the powder coating material from the powder cartridge and the entrained powder coating material is charged in the ionizing field created by an emitter. The replaceable cartridge contains an inlet line and an outlet line oriented in a manner that allows the powder gun to be positioned in different angles and orientations with minimal risk of a powder spill from the powder coating gun. The powder cartridge contains a lid for supporting an inlet line and a body part constructed of clear or translucent material that allows the user to easily view the color of the powder. An electric power supply is used to power the fan and the emitter. A trigger is present in the handle of the powder coating gun and both controls the speed of the fan and enables the charge to the emitter.

Abstract: A charging system includes an alternator body, rotor coil and stator windings. A bridge rectifier is positioned within the alternator body and connected to the stator windings for rectifying the electrical output from the stator windings. The rectifier includes a positive and negative heat sinks each having a top surface and spaced from each other with cooling fins on an outer surface of each heat sink. A plurality of diodes are positioned at each top surface of positive and negative heat sinks. A terminal assembly interconnects respective pairs of positive and negative diodes. At least one pair of interconnected positive and negative diodes are positioned offset from each other at an angle to provide a maximum surface area for the cooling fins.

Abstract: A method of manufacturing a diode assembly used in rectifier assemblies of engine-driven generators is disclosed. The diode assemblies have diode cups, semiconductor diode dies and diode leads fitted therein. The diode subassemblies are reflow soldered, such that the semiconductor diode die and diode lead are reflow soldered within a diode cup in an argon/hydrogen atmosphere. In another aspect of the present invention, a lead loader having a removable lead holder that holds diode leads therein is positioned over a diode boat such that the diode leads are aligned with respective diode cups. The lead holder is slid from the lead loader so that the diode leads fall into the center cups which also have the semiconductor die positioned therein. The diode boat is inserted within a furnace for reflow soldering.

Abstract: A voltage regulator includes a voltage regulator body and connectors carried by the body, which connect to devices controlled by the voltage regulator. A substrate board is received in a board receiving cavity of the voltage regulator body and includes a metallic base layer, an insulator layer on the metallic base layer, and a circuit layer on the insulator layer and defining a printed circuit pattern. Active and passive voltage regulator components are mounted on the substrate board and interconnected by the printed circuit pattern to form a voltage regulating circuit. Terminal connections, such as conductive pins, are secured to the substrate board and operatively connected to selected active and passive components or printed circuit pattern and extend from the substrate board for interconnecting the connectors carried by the voltage regulator body.

Abstract: A rectifier for a 3G, 6G series alternator includes circular configured negative heat sink and an arcuate configured positive heat sink secured to the negative heart sink and separated by an insulator. A plurality of negative and positive diodes is received at each of the respective negative and positive heat sinks. A terminal assembly interconnects negative and positive diodes, and includes extended stator lead connectors that connect to the stator leads of the alternator.

Abstract: An alternator system includes a permanent magnet alternator, battery and voltage regulator operatively connected to the permanent magnet alternator and battery for regulating the charging of the battery. The voltage regulator includes a rectifying circuit for rectifying the alternating current and a semiconductor switching element operative for turning the regulator on and off based on a predetermined temperature threshold to prevent overheating of any voltage regulator electronic components.

Abstract: An ignition system for a vehicle includes a distributor having with a Hall Effect stator assembly and ignition module formed preferably as a thick film integrated (TFI) module, which receives a spark output (SPOUT) signal from an electronic control assembly (ECA). The ignition module includes a microprocessor for generating a control signal to an ignition coil and switching ON and OFF the primary current therein. A temperature sensing circuit is operative with the microprocessor for reducing the duty cycle or overall current or power as applied to the control signal from the TFI ignition module to the ignition coil and reducing the heat generated by the TFI ignition module when a temperature threshold for the TFI ignition module has been exceeded.

Abstract: An ignition system for a vehicle includes a distributor having with a Hall Effect stator assembly and ignition module formed preferably as a thick film integrated (TFI) module, which receives a spark output (SPOUT) signal from an electronic control assembly (ECA). The ignition module includes a microprocessor for generating a control signal to an ignition coil and switching ON and OFF the primary current therein. A temperature sensing circuit is operative with the microprocessor for reducing the duty cycle or overall current or power as applied to the control signal from the TFI ignition module to the ignition coil and reducing the heat generated by the TFI ignition module when a temperature threshold for the TFI ignition module has been exceeded.

Abstract: An ignition system includes an ignition coil, electronic control module that generates a signal, a distributor having a reluctor assembly, and an ignition module for receiving a signal from the electronic control module (ECM) and reluctor assembly. The ignition module includes a microprocessor for generating a control signal to the ignition coil and switching ON and OFF the primary current therein and reducing the duty cycle as applied to the control signal from the ignition module to the ignition coil.

Abstract: An ignition system for a vehicle includes a distributor having with a Hall Effect stator assembly and ignition module formed preferably as a thick film integrated (TFI) module, which receives a spark output (SPOUT) signal from an electronic control assembly (ECA). The ignition module includes a microprocessor for generating a control signal to an ignition coil and switching ON and OFF the primary current therein. A temperature sensing circuit is operative with the microprocessor for reducing the duty cycle or overall current or power as applied to the control signal from the TFI ignition module to the ignition coil and reducing the heat generated by the TFI ignition module when a temperature threshold for the TFI ignition module has been exceeded.

Abstract: A thermal transfer container is disclosed for a semiconductor component to transfer heat to a heat sink such as used in rectifiers for alternators. The thermal transfer container includes an outer cylindrical surface having threads that engage threads defined in the heat sink bore for electrically and thermally connecting the metallic cylindrical container to the heat sink.

Abstract: A voltage regulator is part of a vehicle charging system having an alternator or generator and field winding and connected to a vehicle battery and devices for supplying a voltage and powering vehicle devices. The voltage regulator includes a microcontroller operative for monitoring output voltages representative of monitored load changes within the vehicle. A power output circuit is operatively connected to the microcontroller and connects to a field winding. The microcontroller is operative for changing the field duty cycle of the generator or alternator by turning ON and OFF the power output circuit in a predetermined manner as established by the microcontroller based on monitored load changes.

Abstract: A rectifier and method for forming the rectifier for an internal alternator regulator (IAR) style alternator includes an integrally formed rectifier body having a ground engaging surface that mounts within the alternator and is grounded through an automotive grounding system. A diode receiving cavity is opposite the ground engaging surface A plurality of negative diodes are secured within the diode receiving cavity and grounded thereto. An insulated conductor substrate is positioned in the diode receiving cavity and has a conductive surface that is insulated from the rectifier body and negative diodes. Positive diodes are secured on the insulated conductive substrate. A terminal connector interconnects negative and positive diodes in a preferred bridge rectifier configuration.

Abstract: A rectifier and method for forming the rectifier for an internal alternator regulator (IAR) style alternator includes an integrally formed rectifier body having a ground engaging surface that mounts within the alternator and is grounded through an automotive grounding system. A diode receiving cavity is opposite the ground engaging surface. A plurality of negative diodes are secured within the diode receiving cavity and grounded thereto. An insulated conductor substrate is positioned in the diode receiving cavity and has a conductive surface that is insulated from the rectifier body and negative diodes. Positive diodes are secured on the insulated conductive substrate. A terminal connector interconnects negative and positive diodes in a preferred bridge rectifier configuration.