Abstract: A high power density generator includes a rotor assembly, a rectifier assembly, and a cooling assembly configured in such a way so as to provide high electrical output power while retaining a small profile. The rotor assembly includes one or more rings configured to secure the main rotor windings to the main rotor poles by imparting a clamping force therebetween while conforming to the windings' profile allowing for operation at high RPM and high levels of shock and vibration. The rotor assembly may further include a rotating rectifier assembly positioned so as to reduce the moment arm between the mass centers of the rotor assembly and the drive-end bearing. The rectifier assembly comprises a rectifier housing and one or more rectifiers which are placed radially so as to dissipate heat directly into the airstream. The cooling assembly, comprising a fan and a shroud, is placed adjacent to the rectifier assembly providing immediate cooling of the rectifier.

Abstract: A rotating rectifier assembly includes a metallic housing, a composite substrate, and a rectifier subassembly that can be used to rectify a polyphase AC current. The composite substrate includes a ceramic component and one or more metallic components according to a metallization process. The composite substrate and rectifier subassembly may be positioned in an annular cavity within the metallic housing. In applications where excessive heat and/or shock and vibration are present, an encapsulant may be used to fill the annular cavity.