Patent Publication Number: US-6661662-B2

Title: Vehicular modular design multiple application rectifier assembly

Description:
RELATED APPLICATION 
     This application is based upon prior filed copending provisional application Serial No. 60/270,386 filed Feb. 21, 2001. 
    
    
     FILED OF THE INVENTION 
     This invention relates to rectifier assemblies, and more particularly, this invention relates to rectifier assemblies used with engine-driven alternating current generators and methods of constructing same. 
     BACKGROUND OF THE INVENTION 
     Engine-driven alternating current generators require rectifier assemblies for rectifying alternating current into a direct current suitable for use with automotive electronic components. Typically, automotive rectifier assemblies use heat sink plates that include press fit diodes. 
     Examples of rectifier assemblies as described include those rectifier assemblies disclosed in commonly assigned U.S. Pat. No. 5,451,823, issued Sep. 19, 1995, and U.S. Pat. No. 5,991,184, issued Nov. 23, 1999, the disclosures which are hereby incorporated by reference in their entirety. 
     Some of the prior art rectifiers, however, do not have adequate diode electrode clearance, efficient diode positioning, and adequate ventilation for cooling the diodes. 
     U.S. Pat. No. 4,952,829, Armbruster et. al. discloses a single insulator, conductor embedded integument that is positioned between two heat sinks formed as electrically conductive plates that can correspond to negative and positive heat sinks that receive respective negative and positive diodes. The integument encloses embedded conductor leads for interconnecting the diodes, stator leads, and other components used in these rectifier assemblies. This type of integument typically includes a single circuit board. The single integument interconnects seventeen diodes and six stator leads of an alternator stator, corresponding typically to the non-rotating part of the structure. The complexity of these single integuments with embedded conductors sometimes requires the formation of multilayer conductors that are electrowelded to form a desired circuit configuration. If an electroweld is weak or improperly fabricated, it is not possible to perform a visual inspection after the conductors are embedded. 
     This relatively large, single integument also restricts the air flow between the outer and inner conductive plates. Because rectifier diodes are located near the end of these plates, the diodes are not sufficiently cooled and are prone to failure. Furthermore, each different alternator application requires an expensive mold to manufacture a single circuit board for the integument, resulting in a large inventory of parts. Furthermore, as new alternator applications develop, a single integument as described requires extensive design and tooling changes, even with simple design changes. Also, a single conductor embedded integument restricts equalized heat dissipation because it is not symmetrically formed. 
     In U.S. Pat. No. 5,331,231, Koplin et. al., a threaded bolt is used as an output terminal and positioned between two rectifier plates. This bolt is mounted from the inner side of an outer rectifier plate and held in position by a common, threaded nut on the outer side of the rectifier plate. The threaded bolt is placed between two conductor plates, which receive press fitted rectifier diodes. These plates are electrowelded to opposite sides of the single integument, making the removal and replacement of the threaded bolt impractical. No particular advantage has been gained by securing the bolt with a common nut, which is also subject to loosening by vibration. The additional production step required for assembly of this rectifier is not advantageous. 
     SUMMARY OF THE INVENTION 
     In accordance with the present invention, a rectifier assembly and method of forming same is disclosed, which can be used on a variety of applications of various output current capacities and external connectors by using a small number of universal and specially designed components that minimize tooling costs and reduces the inventory of single application components, which may have a questionable usage rate. The present invention also improves the performance of single application type components by increasing the speed of assembly, and allowing a robust and sturdy rectifier assembly construction that can withstand severe vibration and extreme temperature variations, and have an extended thermal cycling life and corrosion protection. Each rectifier assembly can be used specifically for an intended application. 
     The rectifier assembly of the present invention includes opposing, substantially identical heat sink plates that are interchangeable as either positive or negative heat sinks. Three identical standoffs with snap in wedges are located at key mounting areas Three identical stator guides “snap in” for an interconnection between the stator lead and diode anode leads. Three identical center tap guides that “snap in” use the tabs. It is possible to electroweld a preformed semicircular conductor ring and other preformed conductors if center tapped diode connections are required. A trio diode mount connects smaller preformed diodes to stator leads. A stud, spade, threaded, or side connector allows external interconnects in any combination for a required specific application. 
     The rectifier assembly of the present invention 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 polarity 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. Standoffs can be formed of an insulator material and mounted between the two heat sink plates for separating the two plates and can be mounted by snap fit connection. Component attachment positions are formed on the heat sink plates for receiving a stator lead guide, center tap guide, threaded output terminal, trio diode mount for field excitation diodes, standoffs, side connectors, stud terminal, or spade terminal. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     Other objects, features and advantages of the present invention will become apparent from the detailed description of the invention which follows, when considered in light of the accompanying drawings in which: 
     FIG. 1A is an exploded, isometric view of the negative heat sink and associated components in a first embodiment of the rectifier assembly of the present invention. 
     FIG. 1B is an exploded, isometric view of positive heat sink and associated components of a first embodiment of the rectifier assembly using a side connector. 
     FIG. 1C is an exploded, isometric view of a positive heat sink and associated components of a second embodiment that is used with the negative heat sink of FIG.  1 A and showing use of stud and spade connectors. 
     FIG. 2 is an isometric view of the rectifier assembly components shown in FIGS. 1A and 1B and assembled in final form. 
     FIG. 3 is an isometric view of the rectifier assembly components shown in FIGS. 1A and 1C and assembled in final form. 
     FIG. 4 is another exploded, isometric view of the rectifier assembly shown in FIG. 2 showing separated heat sink plates and showing details of the interconnects as shown in FIGS. 1A and 1B. 
     FIG. 5 is another exploded, isometric view of the rectifier assembly shown in FIG. 3 showing separated heat sink plates and showing details of the interconnects shown in FIGS. 1A and 1C. 
     FIG. 6 is an isometric view of a third embodiment of the rectifier assembly of the present invention that uses the basic components shown in FIGS. 1A and 1C, but showing a larger heat sink plate capable of mounting twice the number of rectifier diodes for applications requiring a higher output current. 
     FIG. 7 is an isometric view of a forth embodiment of the rectifier assembly of the present invention that is similar to FIG. 6, but using a different output interface obtained by removing a stud terminal and replacing it with a spade terminal. 
     FIG. 8 is an exploded, isometric view of the rectifier assembly shown in FIG. 6 with separated heat sink plates and showing details of the interconnects shown in FIGS. 1A and 1B. 
     FIG. 9A is an isometric view of the threaded bolt and insulated shoulder washer used in the present invention. 
     FIG. 9B is an isometric view of the threaded bolt and insulated shoulder washer shown rotated 180 degrees from the view shown in FIG.  9 A. 
     FIG. 9C is an isometric view of the threaded bolt pressed into the heat sink plate as shown in phantom lines. 
     FIG. 9D is an isometric view of the threaded bolt pressed into the heat sink plate before the crimping operation. 
     FIG. 9E is an isometric view of the threaded bolt pressed into the heat sink plate after the crimping operation. 
     FIG. 9F is an isometric view of the threaded bolt pressed into the heat sink plate after the crimping operation, and showing the negative heat sink plate in phantom lines and showing placement of the shoulder washer. 
     FIG. 10A is an isometric view of the stator guide conductor embedded integument in phantom lines and showing details of the embedded conductor. 
     FIG. 10B is an isometric view of the stator guide conductor embedded integument with the three identical guides laid out in a rectifier assembly. 
     FIG. 11A is an isometric view of the stator guide conductor embedded integument in phantom lines and showing details of the conductor used for high capacity generators. 
     FIG. 11B is an isometric view of the stator guide conductor embedded integument and showing three identical guides in the positions used in rectifier assemblies and showing optionally formed conductors for parallel diode rectifier applications. 
     FIG. 12A is an isometric view of the center tap guide conductor embedded integument in phantom lines and showing details of the conductor. 
     FIG. 12B is an isometric view of the center tap guide conductor embedded integument and three identical guides with an optionally formed conductor for a center tap diode rectifier and a conductor ring to terminate stator lead ends and form a stator wye circuit. 
     FIG. 12C is an isometric view of the center tap guide conductor embedded integument and showing three identical guides and an optionally formed conductor for a center tap diode rectifier application and a conductor ring to terminate stator lead ends and form a stator wye circuit, after the electroweld process. 
     FIG. 13A is an isometric view of the standoff. 
     FIG. 13B is an isometric view of the insulated washer. 
     FIG. 13C is an isometric view of the eyelet shown before the crimping operation. 
     FIG. 13D is an isometric view of the eyelet shown after the crimping operation. 
     FIG. 13E is an exploded, isometric view of the eyelet, washer, and standoff. 
     FIG. 13F is an isometric view of the eyelet, washer, and standoff in assembled form before the crimping operation. 
     FIG. 13G is an isometric view of the eyelet, washer, and standoff in assembled form after the crimping operation. 
     FIG. 13H is an isometric view of the eyelet, washer, and standoff in assembled form and mounted on a heat sink plate and showing the other, identical heat sink plate in phantom and snapped into position over three identical standoff assemblies. 
     FIG. 14A is an isometric view of the side connector that can be used in the present invention. 
     FIG. 142 is an isometric view of the side connector of FIG. 14A, but inverted 180 degrees to show details of its lower side. 
     FIG. 14C is an isometric view of the side connector and insulator integument in phantom form, and showing the embedded conductors. 
     FIG. 15A is an isometric view of the stud connector and insulator integument in phantom lines, and showing the embedded conductors. 
     FIG. 15B is an isometric view of the stud connector. 
     FIG. 15C is an isometric view of the stud connector rotated 45° on a vertical axis. 
     FIG. 16A is an isometric view of the spade connector and insulator integument in phantom lines, and showing the embedded conductors. 
     FIG. 16B is an isometric view of the spade connector. 
     FIG. 16C is an isometric view of the spade connector and 45° on a vertical axis. 
     FIG. 16D is an isometric view of the spade connector shown in FIG. 16C, but showing a variation on the shape of the lower conductor for use in a different rectifier application. 
     FIG. 17A is an isometric view of the trio diode conductor embedded integument mount and the insulator integument in phantom lines, and showing the embedded conductors. 
     FIG. 17B is an exploded view of the trio diode conductor embedded integument mount and associated subassembly components, including three diodes having preformed leads and an eyelet. 
     FIG. 17C is an isometric view of the trio diode conductor embedded integument mount rotated 180° from the view shown in FIG.  17 B. 
     FIG. 17D is an isometric view of the trio diode conductor embedded integument mount rotated 180° from the view in FIG. 17B, and showing the diodes of FIG. 17B snapped into position and prepared for electrowelding of the cathode leads to the embedded conductor. 
     FIG. 17E is an isometric view of the trio diode conductor embedded integument mount that is secured by eyelets onto heat sink plates. 
     FIGS. 18-28 show a rectifier assembly of the present invention where the lead frame is placed to the outside of the heat sink plates instead of between the heat sink plates. 
     FIG. 18 is an exploded isometric view showing separated heat sink plates and relative positioning of positive and negative diodes that face the same direction. 
     FIG. 19 is an isometric view of the positive heat sink and showing diodes mounted therein. 
     FIG. 20 is an isometric view of the negative heat sink and showing diodes mounted therein. 
     FIG. 21 is an isometric view of the lead integument. 
     FIG. 22 is an isometric view of the negative and positive heat sink plates secured together. 
     FIG. 23 is another isometric view of the lead integument of another embodiment that has the side vehicle connector mounted thereto. 
     FIG. 24 is an isometric view of the positive and negative heat sink plates connected together for use with the lead integument shown in FIG.  23 . 
     FIG. 25 is an isometric view of the assembled rectifier assembly shown in FIGS. 21 and 22. 
     FIG. 26 is an isometric view of the assembled rectifier assembly shown in FIGS. 23 and 24. 
     FIG. 27 is another isometric view of the assembled rectifier assembly shown in FIG.  25  and showing various components and phantom lines to show the conductors. 
     FIG. 28 is an isometric view of the lead integument without various conductors mounted therein. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     The present invention will now be described more fully hereinafter with reference to the accompanying drawings, in which preferred embodiments of the invention are shown. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. Like numbers refer to like elements throughout. 
     The present invention allows for the construction of rectifier assemblies for engine-driven alternating current generators where a family of different capacity rectifier assemblies can be used, each having variations in the heat sink plate area. Internal connectors are common and the physical nature of various subcomponents used in the rectifier assembly are similar. In the present invention, two identical metallic semicircular plates are used as heat sink plates and can be either positive or negative rectifier heat sink plates as dependent on the polarity of the press fit diode electrodes in press fitted specific hole locations. The advantage of such a structure and method is a reduced tooling cost and increase in production volume, as opposed to using two dissimilar plates dedicated to each function. The rectifier assembly design of the present invention permits a cross airflow for maximum cooling. Any holes without press fit diodes serve a dual function and permit electrode clearance and rapid electrowelding of the electrode and of the diodes to a predetermined shape of conductor embedded integument. All diode specific holes can serve to contain a diode or provide for electrode clearance and ventilation. Therefore, all holes provide a useful function and are not stamped merely for the sake of having a common plate for both positive and negative diode functions. 
     Any stator guides, center tap guides, trio diode mount, standoffs, side connector, stud terminal and spade terminal are fabricated to snap fit into the plates for rapid assembly and electrowelding to respective termination points. Therefore, the components are made to minimize any restriction to air flow. This is an important consideration because the only air path exists from the outer plate, through the components, through the inner plate, through the generator and housing and through the rotor-driven fan. 
     In another aspect of the present invention, the plates are mounted together and an integument acting as an outer lead frame is placed to the outside of the heat sink plates as shown in FIGS. 18-28. A threaded bolt can be used in a manner that is press fit into the outer side of an outer plate and crimped or riveted on the inner side of the plate with a shaft extension fitted into an insulated washer to fit in the corresponding hole of the inner plate for radial stability. 
     FIGS. 1A and 1B show components forming the rectifier assembly of one embodiment of this invention. Each of the components are rotated 45° toward the viewer from a plane projected at the eye level of the viewer. FIG. 1A illustrates the following major components or component groups: a negative (or lower) heat sink plate  100 ; stator lead guide  200 ; center tap guide assembly  300 ; press fit type rectifier diodes  400 ; a threaded bolt insulated washer  501 ; a filter capacitor  600 ; and filter capacitor connector standoff  601 . 
     FIG. 1B illustrates a first embodiment of the present invention operative with the negative heat sink plate  100  and illustrates the following components, or component groups: positive heat sink plate  100 ; rectifier diodes  401 ; threaded output terminal  500 ; filter connector standoff  601 ; trio diode mount  700 ; trio or field excitation diodes  701 ; trio mount eyelet  702 ; standoff supports  800 ; eyelet insulators  802 ; securing eyelets  802 ; and side vehicle connector  900 . 
     FIG. 1C illustrates a second embodiment of the present invention and operative with the components and heat sink plate shown in FIG.  1 A and showing the following components, or component groups where similar functional components have the same reference numerals as identified above: positive heat sink plate  100 ; rectifier diodes  401 ; threaded output terminal  500 ; filter connector standoff  601 ; trio diode mount  700 ; trio or field excitation diodes  701 ; trio mount eyelet  702 ; standoff supports  800 ; eyelet insulators  802 ; securing eyelets  802 ; trio diode output stud  1000 : and stator output spade terminal  1100 . 
     Referring once again to FIG. 1B, the order of assembly for the rectifier assembly is now described. The positive heat sink plate  100  is formed of either aluminum or copper material. Rectifier diodes  401  are press fit into their respective holes, as indicated by the center lines. Threaded output terminal  500  is formed of a typically metallic material and is both pressed and riveted via its own machined lip into its respective hole in plate  100 . Filter capacitor connector standoff is made of metallic, conductive material and is both press fitted and riveted into its respective hole in plate  100 . Standoffs  800  can be made from plastic or other insulator material and are snapped into their respective holes into plate  100  as denoted by the center lines from underneath. 
     Eyelets  802  can be made from a metallic material and are shown with the insert end after the rivet operation. The eyelets  802  are pushed through an insulating washer  801  and through the receiving hole in the standoff  800 , where the riveting operation is accomplished for each of the three identical standoffs  800 . Preformed, axial lead diodes  701  are snapped into preformed slots (not shown in FIG. 1B) in trio mount  700  and electrowelded to the respective, embedded conductor pads. The mounting extrusions of the trio mount slide into the receiving slots of plate  100  and are secured with an eyelet  702  as shown after riveting operation. The connector  900  is snapped into its respective hole in plate  100  and the mating conductors relative to the mount  700  are electrowelded. 
     Referring to FIG. 1A the three stator guides  200  and the three center tap guides  300  with the conductor  301  are snapped into the respective holes in the lower side of plate  100  of FIG.  1 B. The anode conductors of center tap guide  300  and stator guides  200  can both be crimped and electrowelded to their respective rectifier diode anodes. Rectifier diodes  400  are pressed into their respective holes in the negative heat sink plate  100 . The filter capacitor connector standoff  601  is pressed and riveted into its receiving hole in plate  100 . This subassembly is snapped unto the upper assembly as previously described, where the remaining negative rectifier anode leads of diodes  400  are crimped and electrowelded to the respective anode tabs of stator guides  200  and center tap guide  300 . The capacitor  600  is soldered to respective standoffs  601 , which are mounted in both positive and negative plates  100  and adhesive attached, such as epoxy, to the nearest support standoff  800  to complete the assembly. 
     The rectifier assembly structure shown in FIGS. 1A and 1C uses the same assembly procedure as described for FIGS. 1A and 1B, except there is no side connector  900 , and the stud connector  1000  and spade connector  1100 , shown in FIG. 1C, are inserted in the same assembly order as when the side connector  900  had been assembled. Trio mount  700  in either FIG. 1B or FIG. 1C has cut off the unused stud connector tab or the unused side connector tab. 
     FIG. 2 shows the assembled rectifier assembly of FIGS.  1 A and FIG.  1 B. FIG. 3 shows the assembled rectifier assembly of FIGS. 1A and 1C. Each rectifier assembly as shown in FIGS. 2 and 3 is for a different application. Each rectifier assembly is custom assembled for its intended application. All of the components parts, with exception of side connector  900 , stud connector  1000 , and spade connector  1000 , are identical to each other. Thus, in accordance with the present invention, two rectifier assemblies for two different applications with different types of terminals, each with a custom appearance, can be manufactured with a minimal investment in tooling cost and without the additional investment in inventoried components. 
     The thermal conductor heat sink plate  100  is formed of either aluminum or copper construction, and is dimensioned for mounting in direct contact with a generator, such as used in automobile applications. The diode receiving holes as described before are sized to receive press fit diodes in a metal displacement fashion and provide an air tight seal and maximum electrical and heat conductivity to the heat sink. The lower contact area of diodes are pressed flush to the lower surface of a heat sink for additional electrical and heat conductivity to the generator. Other holes can be provided as clearance holes for the rectifier assembly to the generator end frame attaching screws (not shown). The holes receive integument insulated standoffs to provide alignment for quick assembly and insulation to the cooling plate. Other holes can permit nonconducting passage of an electrode bolt. Joining press fit diodes flush with heat sink plates by manual or semiautomatic assembly techniques rapidly completes the plate subassembly for reduced manufacturing costs. 
     FIG. 4 shows the rectifier assembly of FIG. 2 using the identical negative and positive heat sink plates and separated from each other to show details of the component interconnects of FIG.  2 . Each diode  400 , 401  is free from surrounding integument type obstructions to permit the maximum air flow circulation. Air that is drawn through any negative diode  400  lead clearance hole is directed laterally and downward as viewed in the drawing through the positive diode  401  clearance hole, thus, creating a turbulence for maximum cooling. The stator guide  200  embedded conductors are firmly seated in each integument on one end and electrowelded to their respective diode leads on the other end to provide a robust interconnection, while providing minimum resistance to air flow movement. 
     In a similar fashion, the anode leads of the trio diodes that are mounted in trio diode mount  700  are electrowelded with respective paired negative main rectifier diodes  400 , thus, augmenting the rigidity of the assembly. The side connector  900  has one embedded conductor electrowelded to the mating, embedded conductor of the trio mount  700 . The other lead of the side connector is paired with a respective positive diode  401  and electrowelded to respective stator guide  200  embedded conductor. 
     The semicircular center tap conductor is electrowelded to respective tabs on center tap guides  300 . Corresponding grooves in stator guides  200  lock the center tap conductor for rigidity. The standoff  601  is both press fitted and riveted to heat sink plates  100  in direct line with capacitor leads  600 . The leads are soldered to the standoffs to minimize the series resistance and inductance of the capacitor for maximum transient filtering. It also minimizes the effects of corrosion. Appropriate conductor and appearance areas are masked off and finished with an electrostatically applied, powdered epoxy fluid bed protective coating for durability, non-external electrical conductive insulation, and corrosion resistance. 
     FIG. 5 shows the rectifier assembly of FIG. 3 with separated negative and positive heat sink plates  100  and showing details of the component interconnects of FIG.  3 . FIG. 5 shows threaded bolt terminal  500  mounted in a different location than that location shown in FIG. 4 to accommodate the requirements of a different application. FIG. 5 also shows the removal of the side connector  900  shown FIG. 4, and the installation of stud terminal  1000  and spade terminal  1100 , which are used for specific rectifier application. The stud terminal  1000  is electrowelded to an opposing terminal on trio mount  700 , whereas the previously used terminal shown in FIG. 4 was severed. The spade terminal  1100  is electrowelded similar to the terminal on side connector  900  (FIG.  4 ). Thus, with the addition of two relatively inexpensive components, and using the components shown in the rectifier assembly of FIG. 4, an entirely different application is produced for a rectifier assembly. 
     FIG. 6 shows a high current output version of a rectifier assembly of the present invention using most of the modular components shown in FIGS. 1A and 1C, except a larger heat sink plate  100   a  is used that is capable of mounting two main rectifier diodes  400 , 401  in each leg of a three phase “wye” circuit. Both positive and negative heat sink plates  100   a  are identical to reduce tooling and inventory cost. The heat sink plates are also designed for mounting center tap fed main diodes. Key components include the main rectifier diodes, the spade terminal  1100  and stud terminal  1000 . 
     FIG. 7 illustrates another rectifier assembly used in a different application. Parallel and center tap diodes and the stud terminal  1000  are no longer used. The spade terminal  1100  has been moved as shown in FIG. 7, different from its location shown in FIG.  6 . The requirements of an entirely different application are met with no additional tooling cost or expenditures in inventory. 
     FIG. 8 shows the rectifier assembly of FIG. 6 having the identical negative and positive heat sink plates  100   a  separated from each other to show details of the component interconnects of FIG.  6 . FIG. 8 is an entirely different application for the rectifier assembly as compared to the rectifier assembly shown in FIG. 5, but shares the same assembly methods and design characteristics as explained with reference to FIG.  4 . The identical components are used except a larger and identical heat sink plate is shown as referenced by the “a” suffix in FIG. 8. A larger diameter center tap conductor ring is electrowelded to the identical center tap guides  300  and to the extended length embedded conductor, but it is embedded into the same mold to form stator guide  200  in FIG. 5 or stator guide  200   a  in FIG.  8 . Thus, with a few metal stampings used in place of identical metal stamping as shown in FIG. 5, a rectifier assembly of professional and custom appearance is produced with parallel rectifier diodes, a larger diameter heat sink, and an approximate doubling in output current capacity, but with minimum investment in both tooling and inventory cost. 
     FIGS. 2 and 8 show the differences in actual physical size of the rectifier assemblies, but they are shown in intermediate sizes of different application rectifiers that share the modular components of FIGS. 2 and 8, and the resultant advantages of this invention. 
     FIG. 9A illustrates a threaded battery terminal stud  500  and mating insulating shoulder washer  501 . The shaft  506  is of a dimension to fit within the center hole  507 . FIG. 9B rotates the view shown in FIG. 9A 180° to illustrate details of the bottom of the stud  500  and washer  501 . Referring to FIG. 9B, the extended diameter portion  502  acts as a stop, thus, limiting movement of the stud  500  when it is pressed into its corresponding hole in the heat sink plate  100  or  100   a  as shown in FIG.  9 C. 
     Referring now to FIG. 9B, the serrated section  503  bites into the plate hole to prevent rotation and provide a corrosion resistant seal to the plate. The lip  505  is shown in its preriveted state, thus, permitting insertion clearance in the corresponding plate hole. FIG. 9 c  shows the stud  500  positioned in the corresponding hole of plate  100  (shown in phantom view). FIG. 9D shows threaded bolt  500  pressed into the corresponding plate  100  (or  100   a ) hole before the riveting operation. FIG. 9E shows the same threaded bolt as in FIG. 9D after the riveting operation, which provides vibration free mechanical and an air tight corrosion resistant attachment with maximum contact area for a low resistant electrical connection. FIG. 9F details the final threaded bolt  500  and insulating washer  501 , the lower or positive plate  100  or  100   a,  and the upper or negative plate  100  or  100   a  in phantom view, illustrate the robustness and simplicity of this portion of the rectifier assembly. 
     FIG. 10A shows the stator guide conductor embedded integument. The plastic insulator portion is shown in phantom view. The embedded conductor can be stamped and shaped as single form, with no internal welds, resulting in maximum conductivity. Alternator stator leads (not shown in detail) are guided upward through passage  206  and slightly beyond crimp terminal  201 . After lead passage, the terminal portion  201  is crimped and electrically welded for both mechanical and electrical integrity. The terminal portion  203  slides over the pressed-in positive diode lead  401  and it is crimped and electrowelded as illustrated in FIG.  8 . The terminal portion  202  receives the negative diode lead  400  and the corresponding trio diode lead in a similar fashion and is crimped and welded. Both upper and lower surfaces  205  act as stops to separate precisely the plates  100 ,  100   a.  Upper and lower wedges  204  lock the stator guide  200  into corresponding holes in plates  100 ,  100   a  to aid in the assembly process. 
     FIG. 10B shows the three identical stator guides of FIG. 10A drawn in the positions they would occupy if inserted into the corresponding holes in plates  100 ,  100   a.  In accordance with the present invention, the three stator guides  200  as shown in FIG. 10B are identical and suitable for a multiple rectifier assembly applications. 
     FIG. 11A shows an adapted stator guide of FIG. 10A, where the insulated plastic integument shown in the phantom lines of FIG. 11A is identical to the integument shown in FIG.  10 A. The embedded conductor of FIG. 11A is similar in construction to the embedded conductor shown in FIG.  10 A. One major difference is the length of the arm that resides between the terminal portions  203   a  and  202   a  and the plastic integument. In FIG. 11A, this arm is made longer to accommodate rectifier assemblies of a larger output current capacity. In the present invention, the same molds are used to form the assembly as shown in FIG. 10A, which can be used to form the assembly shown in FIG.  11 A. In this manner, only the conductive portion of FIG. 11A is tooled to host rectifier assemblies of a higher current capacity. FIG. 11B shows the relative locations of the three identical stator guides  200   a  when they are snapped into the corresponding holes in plate  100   a.  An optional parallel diode conductor  209   a  and  210   a  can be electrowelded to the corresponding stator conductors for applications requiring a parallel diode configuration. By manufacturing these parallel diode conductors, a different rectifier assembly application can be accomplished adding these two components. 
     FIG. 12A shows the center tap guide  300  and the plastic insulator portion in phantom form. Top and bottom surfaces  305  control the spacing of the plates and contribute to the overall rigidity of the final rectifier assembly. Both top and bottom wedges  304  permit snapping of the center tap guide into the corresponding plate hole and to aid the assembly process, preventing these components from falling out during handling. The passage  306  guides the stator leads through the integument to just above the terminal  301 . The tabs are crimped and electrowelded to form a corrosion resistant connection. Tab  302  provides a mating surface to the conductor arc  308  (FIG.  12 B). The tab is electrowelded to the arc, which can be formed to various radii to accommodate different rectifier applications. 
     FIG. 12B is an exploded view showing the components used to form the center tap guide assembly. The three identical center tap guides  300  are positioned in a manner that illustrates how they will be inserted into the plate. For applications requiring the use of center tap fed main rectifiers, the conductor  309  is electrowelded to a conductive arm on one of the three center tap guides. The semicircular conductor  308  is electrowelded to the tabs  302 , as previously described. The center tap conductor  309  is formed with a terminal  301  for both crimping and electrowelding to a negative main rectifier diode. The terminal  311  allows conduction to the positive main rectifier diode. Conductor  309  is not required. Where there is no center tap fed. FIG. 12C shows the assembled center tap guide assembly after electrowelding. It can be snapped into the corresponding plate. 
     FIG. 13A shows the universal standoff  800  used on all rectifier assembly applications. Upper and lower surfaces  800   g  provide stops, which precisely space the heat sink plates. The rim  880   b  mates with the corresponding hole in the plate. Through hole  800   e  provides passage for the eyelet  802 , as shown in FIG.  13 C. The rim  800   c  mates with the corresponding hole in the plate to prevent rotation. The hole  880   d  provides an attachment point for a coarse, threaded screw for attaching external devices (not shown). The wedge  800   a  provides a locking mechanism when attaching the negative heat sink plate. Cone  800   f  provides a tapered seat for the riveted end of eyelet  802   b,  as shown in FIG.  13 D. FIG. 13B shows details of the insulating eyelet washer  801 . The washer is symmetrical and can be installed in either direction. The hole  801   a  receives the preriveted end of the eyelet  802   a.  It is formed from a suitable metallic material. FIG. 13D shows the same eyelet of FIG. 13C in the postriveted stage. 
     FIG. 13E is an exploded isometric view of the standoff components. Standoff  800  is inserted into its respective hole in the positive heat sink plate. Insulating washer  801  is dropped onto eyelet  802  and the assembly is inserted into the respective receiving hole in the standoff  800  as shown in FIG.  13 F. The end of the eyelet is formed to secure the components (FIG.  13 G). The rim  800   b  shown in FIG.  13 A and the insulating washer  801  shown in FIG. 13B both insulate the metallic eyelet  802  from the heat sink (shown in phantom lines in FIG.  13 G). FIG. 13H shows the final assembly of the standoff components where three identical standoff subassemblies are attached to the positive heat sink plate  101   a  (or  100  as in FIG.  1 B). The negative heat sink plate  101   a  is shown in phantom view and snaps onto the tangs  800   a  shown in FIG.  13 A. Thus, the standoff  800  can be applied to an entire family of different rectifier assemblies and provide precise nonconductive spacing of the two conductive heat sink plates. The standoff also holds the two plates together and attaches an external accessory (not shown). The standoff also allows an attachment screw to be inserted for mounting the rectifier assembly to a generator. 
     FIG. 14A shows the side connector  900 , and FIG. 14B shows the side connector  900  of FIG. 14A rotated 180° to illustrate provide the detail of the lower portion of side connector  900 . FIG. 14C shows the side connector  900  with the plastic insulator integument shown in phantom lines. As previously described, the side connector  900  is essentially a circuit to output both the rectified field excitation voltage and provide an output of one of the stator end leads. As noted before, the present invention tools one part that serves for different applications independent of the current output capacity of a particular rectifier assembly. 
     The two conductors shown in FIG. 14C are plated to withstand corrosive forces and are stamped and formed to the specific shape. Tabs  901  and  902  receive a suitable mating connector. As the diameter of the rectifiers varies in accordance with the output current capacity, mating conductor ends  903  and  904  can be easily bent to accommodate the rectifier assemblies. For example, the conductive ends  903  can be bent short for smaller diameter rectifier assemblies, whereas end  903   a  could accommodate a larger rectifier assembly. In the actual side connector  900 , either bent  903  or  903   a  could be used, but not both. One side connector assembly always suits the entire family of rectifier assemblies. Wedges  906  and  907  provide a snap in mechanism to hold the side connector to the respective holes in the heat sink plates and facilitate assembly. 
     FIG. 15A shows the studded field excitation connector  1000 , the embedded conductor, and machined stud. Tab  1002  is electrowelded to thw machined stud extension  1007 . This assembly is embedded into the insulator integument. Threaded stud portion  1001  accepts a suitable ring terminal, which is held fast by a mating nut. Integument surfaces  1005  and  1006  provide a stop for the proper heat sink plate spacing. Wedges  1003  and  1004  provide a locking snap action to hold the stud assembly in place during assembly. The view in FIG. 15B emphasizes the curvature of connecting tab  1002 . FIG. 15C shows the same component rotated on a vertical axis, 45° to the right. The single stud connector  1000  serves different applications and reduces tooling and inventory cost. 
     FIG. 16A shows the spade connector  1100  and the embedded conductor. Surfaces  1105  and  1106  provide heat sink spacing. Wedges  1003  and  1006  hold the component securely in the respective holes of the heat sink plates. FIG. 16C shows the spade connector rotated 45° to the right on its vertical axis from the view shown in FIG. 16B, and illustrates how the stud connector  1100  is shown in the assembly drawings. FIG. 16D shows a variation of how the connecting conductor  1102  is formed, as opposed to the conductor in FIG.  16 C. This conductor is crimped and electrowelded with one of the main diode leads. This adapts the spade connector to the family of rectifier assemblies. 
     FIG. 17A shows the field excitation diode mounting integument  700  and the embedded conductor. This module mounts and connects standard, axial aligned lead diodes to rectify the stator voltage and provide a direct current for the field rotor coil (not shown). Conductors  703   a  and  703   b  connect the field excitation voltage to either the side connector  900 , as shown in FIG. 14A, the stud connector  1000  as shown in FIG. 15A, or the spade connector  1100  as shown in FIG.  16 A. The unused conductor  703   a  or  703   b  is sheared off so that the diode mount  700  is universal in all applications. Spring tab  704  is electrowelded to the main embedded conductor for contact with a voltage regulator element (not shown). 
     FIG. 17B is a solid view of the diode mount module shown in FIG.  17 A. The spring tab  704  is drawn to emphasize this particular component. Mushroom type extensions  706  slide into the respective slots in the positive heat sink. The eyelet  702  is inserted into the respective heat sink hole and riveted for a firm, but rapid attachment to said heat sink. Trio or field excitations  701  are shown in the lower portion of FIG.  17 B. Each diode has identically preformed leads and are drawn in the relative position they would sit within the diode mount module. FIG. 17C shows the diode mount of FIG. 17B rotated 180° to provide a bottom view of the mount in FIG.  17 C. Dimples  705  provide a surface where the cathode lead of each respective diode can be electrowelded. FIG. 17D is the same view as FIG. 17C, but with diodes  701  snapped into their respective holders. The three cathode leads are electrowelded to their respective dimples, completing the assembly procedure for this module. FIG. 17E shows the preassembled module of FIG. 17D mounted on the inner side of the positive heat sink plate  100  with the eyelet  702  riveted into position. The anode ends of each diode will be crimped and electrowelded to its respective main diode to complete the field excitation trio diode circuit. 
     FIGS. 18-28 illustrate a further aspects of the present invention where the plastic, insulator integument acting as a lead frame is placed to the outside of the heat sink plates. For purposes of explanation in the drawings, the same reference numerals are used on like components as in the description of FIGS. 1-17E, except they are raised to the two thousand series (2000). 
     As shown in FIGS. 18-28, the positive and negative heat sink plates  2100  are positioned with insulator spacers  2501  to allow fabrication in spaced relation and include a threaded output terminal  2500 . The diodes  2400 ,  2401  are positioned as facing in the same direction and received through the appropriate diode receiving holes, as shown in FIGS. 19 and 20. FIG. 21 shows an insulator lead integument  2300  with other component parts mounted thereon relative to the assembled diode heat sink plates shown in FIG.  22 . These components include field excitation diodes  2701 , eyelet insulators  2802 , filter capacitor  2600 , and the other components operative with these listed components. The stud connector  3000  is mounted on the integument. FIGS. 23 and 24 show the embodiment using the side vehicle connector  2900  instead of the stud connector shown in FIG.  21 . FIGS. 25 and 26 illustrate the assembled rectifier assembly having the insulated lead frame, i.e., integument  2300 , positioned on an outside surface of one of the heat sink diode plates instead of sandwiched between. FIG. 27 shows various portions of the integument and phantom and showing details of the various conductors. FIG. 28 shows details of the insulator forming the integument without conductors with various added formed support mounts and components. Diodes  2701  can be snap fit onto the lead integument by snap fit connectors, as illustrated. Other components can be snap fit as illustrated. 
     This application is related to copending patent applications entitled, “VEHICULAR MODULAR DESIGN MULTIPLE APPLICATION RECTIFIER ASSEMBLY HAVING OUTER LEAD INTEGUMENT,” which is filed on the same date and by the same assignee and inventors, the disclosure which is hereby incorporated by reference. 
     Many modifications and other embodiments of the invention will come to the mind of one skilled in the art having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is to be understood that the invention is not to be limited to the specific embodiments disclosed, and that the modifications and embodiments are intended to be included within the scope of the dependent claims.