Abstract: A vehicle alternator includes front and rear housing members, a Y-connected stator coil and rotor supported by the front and rear housing members, and a rear cover that connects to the rear housing member. A brush holder and rectifier are disposed on the rear housing member and interposed between the rear housing member and rear cover. The rectifier is operatively connected to the Y-connected stator coil. The rectifier includes negative and positive heat sinks having pressed fit diodes received within diode openings. Positive and negative heat sinks are less than five millimeters thick, in one aspect of the present invention. A lead frame is formed of an insulator material and mounted on a side of the positive heat sink opposite the negative heat sink. The lead frame includes embedded conductors and connectors that interconnect diode leads of the rectifier diodes in an electrical rectifying configuration.

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: 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: 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 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 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.

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 rectifier assembly includes two substantially identical and interchangeable heat sink plates mounted parallel to each other in spaced relation. Each heat sink plate has identically positioned diode mounting holes. A plurality of rectifier diodes are mounted within the diode mounting holes. Each diode has a diode electrode. One plate is selectively negative or positive depending on the plurality of diodes mounted within the plate such that one heat sink plate is negative and the other heat sink plate is positive. The diode mounting holes not receiving diodes therein provide diode electrode clearance and ventilation.

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 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 rectifier assembly includes two substantially identical and interchangeable heat sink plates mounted parallel to each other in spaced relation. Each heat sink plate has a plurality of identically positioned diode mounting holes. A plurality of rectifier diodes are mounted within the diode mounting holes such that plates are selectively negative or positive depending on the plurality of diodes mounted within the plate. A lead integument formed from an insulator material is mounted on a heat sink plate opposing the other heat sink plate and has embedded conductors and connectors that interconnect diode electrodes and other rectifier components.

Abstract: A rectifier assembly includes two substantially identical and interchangeable heat sink plates mounted parallel to each other in spaced relation. Each heat sink plate has a plurality of identically positioned diode mounting holes. A plurality of rectifier diodes are mounted within the diode mounting holes such that plates are selectively negative or positive depending on the plurality of diodes mounted within the plate. A lead integument formed from an insulator material is mounted on a heat sink plate opposing the other heat sink plate and has embedded conductors and connectors that interconnect diode electrodes and other rectifier components.

Abstract: A rectifier assembly includes two substantially identical and interchangeable heat sink plates mounted parallel to each other in spaced relation. Each heat sink plate has identically positioned diode mounting holes. A plurality of rectifier diodes are mounted within the diode mounting holes. Each diode has a diode electrode. One plate is selectively negative or positive depending on the plurality of diodes mounted within the plate such that one heat sink plate is negative and the other heat sink plate is positive. The diode mounting holes not receiving diodes therein provide diode electrode clearance and ventilation.

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 rectifier includes a first electrically conductive cooling member having a first surface for direct contact mounting. A second surface has a first set of diode mounting locations. A diode is mounted within each diode mounting location of the first set and has a terminal extending generally normal from the first surface. An electrical insulator overlies the second surface. A second electrically conductive cooling member has a first surface overlying the insulator, and a second surface having a second set of diode mounting locations. The second electrically conductive cooling member has a plurality of slot openings formed in a radial pattern and extending through the second electrically conductive cooling member from the first surface to the second surface.

Abstract: A bridge rectifier assembly includes: a self aligning cloverleaf shaped diode header which sandwiches each diode chip; a semi-circular heat and electrically conductive plate accommodated with receptacles to position the cloverleaf diodes; a heat and non-electrical conductive insulator; a finned heat and electrical conductive extrusion with similar receptacles to position the cloverleaf diodes; an articulated terminal to provide thermal and mechanical stress relief executing an electrode function adhered to the cloverleaf diode header; and a molded insulated integument with embedded electrical conductors of a cantilevered configuration to further alleviate thermodynamic and mechanical stresses. A second embodiment repeats the first embodiment, and includes a heat and electrical conductive plate that is larger in area and with the extrusion succeeded by a second plate of identical outline as the first.

Abstract: A single integrated circuit for multiple vehicle voltage regulator applications is inexpensive, programmable and responsive to mixed signals. The integrated circuit provides both analog and digital functions, and uses a single voltage comparator serving all comparator functions. A variety of features are included with the single integrated circuit in order to permit the programmable, mixed signal and multiple application characteristics of the device.

Abstract: A voltage regulator for regulation of automotive electrical generators and battery system. A generator is coupled through a rectifier to a voltage regulator and a battery. The regulator is activated by a low voltage level stator signal from the generator. The activation voltage level is set to an improved initial activation time when the generator starts to charge the battery while maintaining tolerance to rectifier leakage current. A feedback is included in the regulator to lower power dissipation during regulation and protect the regulator during a voltage surge.