Abstract: Embodiments of the invention provide an electric machine module including a housing. The housing can include a machine cavity. In some embodiments, an electric machine can be at least partially positioned within the machine cavity and can include a stator assembly. The stator assembly includes a stator core with slots. In some embodiments, conductors can be positioned in the slots. The conductors include a turn portion extending between leg portions. The leg portions include an angled portion and a connection portion. The conductors are disposed within the plurality of slots so that the angled and connection portions extend from the stator core at a first axial side. At least one insulation member can be disposed over at least some of the leg portions so that the connection portions are at least partially uncovered.

Abstract: Embodiments of the invention provide an electric machine module including a housing. The module can include an electric machine positioned within the housing. The electric machine can include a field coil and a stator assembly. The module can include a rectifier assembly coupled to the housing and electrically connect to the stator assembly. The rectifier assembly can include at least one output post. A voltage regulator is coupled to the housing and includes at least one field post and a sense post. The voltage regulator is electrically connected to the rectifier assembly. The module can include a remote sense terminal coupled to the housing. A sense switch circuit is electrically coupled to at least the remote sense terminal, the sense post, and the at least one output post.

Abstract: An improvement to a bridge rectifier assembly of the type used to convert alternating current produced by an motor vehicle alternator into direct current. The bridge rectifier assembly of this type comprises a heat sink, a plurality of pressfit diodes installed in the heat sink, and a plurality of terminals electrically connected to the motor vehicle alternator. The first end of a flexible conductor is mechanically and electrically connected to a conductive connector. The second end of the flexible conductor is mechanically and electrically connected to a lead of one of the plurality of pressfit diodes. The conductive connector is electrically connected to one of the plurality of terminals to complete an electrical connection between the one of the plurality of pressfit diodes and the one of the plurality of terminals.

Abstract: An improvement to a bridge rectifier assembly of the type used to convert alternating current produced by an motor vehicle alternator into direct current. The bridge rectifier assembly of this type comprises a heat sink, a plurality of pressfit diodes installed in the heat sink, and a plurality of terminals electrically connected to the motor vehicle alternator. The first end of a flexible conductor is mechanically and electrically connected to a conductive connector. The second end of the flexible conductor is mechanically and electrically connected to a lead of one of the plurality of pressfit diodes. The conductive connector is electrically connected to one of the plurality of terminals to complete an electrical connection between the one of the plurality of pressfit diodes and the one of the plurality of terminals.