Abstract:
A rectifier diode of electric generator applies to electric generators with violent vibrations, especially to those used in heavy-duty vehicles. Good conductivity in the rectifier diode is ensured to enhance stable operations of the electric generators. The rectifier diode has a main body, a conducting fixing component, a flexible conducting wire, and a connecting component. The main body has a cup with a semiconductor device therein and a lead electrically connected to the semiconductor device. The lead protrudes outwards. The conducting fixing component is connected to the lead. The flexible conducting wire is connected to the fixing component. The connecting component is connected to the distal end of the flexible conducting wire.

Description:
BACKGROUND OF THE INVENTION  
       [0001]     1. Field of the Invention  
         [0002]     The present invention relates to a rectifier diode of electric generator and, more particularly, to a rectifier diode disposed in an automobile electric generator to rectify an AC power to a DC power and especially applicable to vehicles with violent vibrations such as heavy-duty vehicles.  
         [0003]     2. Description of Related Art  
         [0004]     A rectifier diode or an embedded type package of power semiconductor device indicates a diode rectifier embedded in a car or used in the industry. The rectifier diode is usually disposed in an electric generator to convert an AC power to a DC power. Because the rectifier diode is located on a high-temperature electric generator, its internal structure needs to have a high stability. Besides, because the rectifier diode is tightly embedded in a rectifier, it needs to endure a very large pressure when embedded into the rectifier.  
         [0005]     The applicant of the present invention has proposed a related disclosure of U.S. Pat. No. 6,455,929B1 titled “embedded type package of power semiconductor device” published in Sep. 24, 2002, wherein an embedded type package of power semiconductor device is provided. This embedded type package of power semiconductor device won&#39;t crack when embedded, hence preventing the semiconductor chip from being incorrectly assembled into a cup. Moreover, a good heatsink structure is accomplished.  
         [0006]     Although the above disclosure really has a good effect, it is found that crack of the lead of the rectifier diode may arise when it is assembled in a vehicle with violent vibrations such as a heavy-duty vehicle, hence causing bad electric connection in an electric generator.  
         [0007]     As shown in  FIG. 1 , a prior art rectifier diode  20   a  is embedded into a heatsink shell  10   a  of a rectifier. The rectifier diode  20   a  has a metallic rod-shaped lead  22   a  electrically connected to a semiconductor device therein. The rectifier has an insulating board  30   a  with a plurality of connecting terminals  40   a . Each connecting terminal  40   a  has a conducting bolt  42   a  protruding upwards, a connecting spacer  44   a  disposed on the top face of the insulating board  30   a , a connecting portion  46   a  extending outwards from the connecting spacer  44   a , and a clamping portion  48   a  formed at the distal end of the connecting portion  46   a . The clamping portion  48   a  clamps the lead  22   a  and is electrically connected to the outside via the conducting blot  42   a.    
         [0008]     Although the above rectifier diode has a firm assembly, the vibrating force may be transmitted into the rectifier diode  20   a  via the rigid lead  22   a  when used in a vehicle with violent vibrations, hence causing bad electric connection of internal devices or even crack of the lead  22   a.    
       SUMMARY OF THE INVENTION  
       [0009]     An object of the present invention is to provide a rectifier diode of electric generator applicable to electric generators with violent vibrations. Crack of the lead can be avoided to ensure good electric connection in the rectifier diode and also enhance the stability of operation of an electric generator.  
         [0010]     Another object of the present invention is to provide a rectifier diode of electric generator, whose external conducting portion has flexibility to bear violent vibrations.  
         [0011]     Yet another object of the present invention is to provide a rectifier diode of electric generator to improve its external conducting portion for simplifying the connection procedures with the outside.  
         [0012]     To achieve the above objects, the present invention provides a rectifier diode of electric generator applicable to electric generators with violent vibrations. The rectifier diode of electric generator comprises a main body, a conducting fixing component, a flexible conducting wire, and a connection component. The main body has a cup and a lead. A semiconductor device is disposed in the cup. The lead is electrically connected to the semiconductor device and protrudes outwards. The conducting fixing component is connected to the lead. The flexible conducting wire is connected to the fixing component. The connecting component is connected to a distal end of the flexible conducting wire.  
         [0013]     Because the flexible conducting wire matches the fixing component and the connecting component, violent vibrations can be endured to ensure good electric connection in the rectifier diode and also enhance the stability of operation of an electric generator. Moreover, the design of the connecting component can simplify the connection procedures with the outside. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS:  
       [0014]     The various objects and advantages of the present invention will be more readily understood from the following detailed description when read in conjunction with the appended drawing, in which:  
         [0015]      FIG. 1  is a local top view of a prior art rectifier diode assembled in a rectifier;  
         [0016]      FIG. 2  shows an exploded side view and an assembly top view of a rectifier diode of electric generator of the present invention;  
         [0017]      FIG. 3  is an assembly top view of a rectifier diode of electric generator of the present invention;  
         [0018]      FIG. 3A  is an assembly top view of a rectifier diode of electric generator according to a second embodiment of the present invention;  
         [0019]      FIG. 4  is an assembly side view of a rectifier diode of electric generator of the present invention;  
         [0020]      FIG. 4 A  is a locally enlarged view of part A in  FIG. 4 ; and  
         [0021]      FIG. 5  is a perspective view of a rectifier diode of electric generator of the present invention when assembled into a heatsink structure of electric generator. 
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0022]     As shown in  FIG. 2 , the present invention proposes a rectifier diode of electric generator  100  applicable to electric generators with violent vibrations. The rectifier diode  100  comprises a main body  10 , a fixing component  20 , a flexible conducting wire  30 , and a connecting component  40 .  
         [0023]     The main body  10  has a cup  12  and a lead  16 . A semiconductor device (not shown) is disposed in the cup  12 . The lead  16  is electrically connected to the semiconductor device and protrudes outwards. A plurality of grooves  122  is provided around the cup  12  to enhance the fixing force of embedding. The lead  16  and the semiconductor device are fixed in the cup  12  by insulating gel  14 . The fixing component  12  is made of material of good conductivity, and is connected to the lead  16 . The flexible conducting wire  30  is connected to the fixing component  20 . The connecting component  40  is connected to the distal end of the flexible conducting wire  30  for connection with an external device.  
         [0024]     The fixing component  20  is made of a metal sheet, and is folded along a fold line  22  to clamp the lead  16  and the flexible conducting wire  30 . In a preferred embodiment of the present invention, the fixing component  20  is made of copper material and plated with nickel alloy. The copper material has a good conductivity. Because the rectifier diode  100  is usually used in a high-temperature environment, the fixing component  20  of copper material is electroplated with nickel alloy to avoid oxidation.  
         [0025]     In this preferred embodiment of the present invention, the connecting component  40  is also made of a metal sheet, and has a fixing portion  42  and an extended portion  44  extending outwards from the fixing component  42 . The fixing portion  42  is a rectangular sheet, and is folded along a fold line  422  to clamp the distal end of the flexible conducting wire  30 . The connecting component  40  is preferably to be made of copper material and electroplated with nickel alloy and avoid oxidation.  
         [0026]     As shown in  FIG. 3 , in order to ensure that the fixing component  20  can firmly connect the lead  16  and the flexible conducting wire  30 , the fixing component  20  is preferably to be welded to the lead  16  and the flexible conducting wire  30 . Welding means the metal of the fixing component  20  is melt and connected with the lead  16  and the flexible conducting wire  30  to achieve a firm connection. A preferred method of welding it to form a beveled shape at a welded position  24  of the fixing component  20 . That is, the fixing component  20  shrinks gradually from the lead  16  to the flexible conducting wire  30 . The welded position  24  of the fixing component  20  forms a beveled shape to have a better welding result. Of course, the welded position  24  of the fixing component  20  can also be of a planar shape.  
         [0027]     The flexible conducting wire  30  is preferably to be a copper braid lead formed by braiding several thin wires. For example, the number of thin copper wires of the flexible conducting wire  30  can reach about  800 . A copper braid lead has a good conductivity. A braid lead with several thin wires has a better flexibility and won&#39;t crack easily. The flexible conducting wire  30  is further electroplated with nickel alloy to avoid oxidation.  
         [0028]     The extended portion  44  of the connecting component  40  is a screwable metal sheet. Speaking more specifically, the extended portion  44  is a ring-shaped metal sheet. The extended portion  44  can thus be conveniently screwed to a conducting bolt with a nut.  
         [0029]     As shown in  FIG. 3A , the extended portion  44  of the connecting component  40  can also be a hook-shaped metal sheet.  
         [0030]     As shown in  FIGS. 4 and 4 A, when the rectifier diode  100  of the present invention is connected, the edge of the fixing component  20  is processed to prevent the sharp edge from damaging the wire due to frequent vibrations. In this preferred embodiment, the fixing component  20  not only has a beveled welded position; it is also connected to one end of the lead  16  to form an outward opening  28 . The opening  28  is bent to be of an arc shape, i.e., the opening  28  forms an upper bevel edge  282  and a lower bevel edge  284 . The smooth upper bevel edge  282  and lower bevel edge  284  are used to achieve a protection effect. Besides, the fixing component  20  is connected to one end of the flexible conducting wire  30  to also form an outward opening  26 . The opening  26  is bent to be of an arc shape, i.e., the opening  26  forms an upper bevel edge  262  and a lower bevel edge  264 .  
         [0031]     The fixing portion  42  of the connecting component  40  is preferably to be welded to the flexible conducting wire  30 . A welded position  420  (shown in  FIG. 3 ) of the fixing portion  42  is also preferred to be of a beveled shape to have a better welding effect. Of course, the welded position  420  can also be of a planar shape. On the other hand, for easy assembly, the extended portion  44  is fixed to a conducting bolt by means of screwing, and an obtuse included angle exists between the fixing portion  42  and the extended portion  44  of the connecting component  40 . The included angle α between the extended portion and the horizontal line is about  
         [0032]      20  degrees.  
         [0033]     In order to protect the flexible conducting wire  30 , the fixing portion  42  of the connecting component  40  is connected to one end of the flexible conducting wire  30  to form an outward opening  46 . The opening  46  is bent to be of an arc shape, i.e., the opening  46  forms an upper bevel edge  462  and a lower bevel edge  464 .  
         [0034]     The other end of the connecting component  40  is an open end  48 . An upper bevel edge  482  is also formed above the open end  48 .  
         [0035]     As shown in  FIG. 5 , the main body  10  of the rectifier diode  100  of the present invention is fixed in a heatsink shell  200  by means of embedding. The flexible conducting wire  30  is bent toward an insulating board  300 . The insulating board  300  has a plurality of conducting bolts  320 . Because the extended portion  44  of the connecting component  40  is a screwable metal sheet, the extended portion  44  can be easily screwed to one of the conducting bolts  320  with a nut  340 . Therefore, the assembly procedures of the rectifier diode  100  can also be simplified without the need of clamping or welding in the prior art.  
         [0036]     The present invention has the following features and functions. 
        1. Because the flexible conducting wire  30  has flexibility and can be firmly connected to the main body  10 , it is applicable to electric generators with violent vibrations to prevent the vibration force from transmission to the rectifier diode  100 , hence ensuring good electric connection in the rectifier diode and also enhancing the stability of operation of an electric generator.     2. The flexible conducting wire  30  can improve the structure of the external conducting portion of the rectifier diode  100  to endure violent vibrations and also simplify the connection procedures with the outside.        
 
         [0039]     Although the present invention has been described with reference to the preferred embodiment thereof, it will be understood that the invention is not limited to the details thereof. Various substitutions and modifications have been suggested in the foregoing description, and other will occur to those of ordinary skill in the art. Therefore, all such substitutions and modifications are intended to be embraced within the scope of the invention as defined in the appended claims.