IMPROVED 10SI ALTERNATOR HOUSING TO ACCOMMODATE LARGER HEAVY DUTY 17SI RECTIFIER

BOITE D'ALTERNATEUR 10SI AMELIOREE POUR CONTENIR UN RECTIFICATEUR 17SI A GRANDE CAPACITE ET DE PLUS GRANDE TAILLE

English Abstract

Briefly, high output "popular" small frame alternators have a high rate of
failure due to higher heat
temperatures typically caused by; 1) continuous higher rate charging, 2) lack
of heat dissipation through
rectifier heat sinks & diodes, 3) insufficient cooling (air exchange/air flow)
through alternator and
components, 4) the "plugging up" of alternator by foreign matter such as
chaff, dust etc...as is common
in agricultural, mining and industrial applications and therefore limiting
cooling causing "burn out".
The invention consists of an improved alternator CE housing to allow for a
larger rectifier with larger
heat sinks (and thus its exposed surface area) and 9 50amp diodes vs. the
original 6 25amp diodes (and
thus increasing its current carrying capability) as well as an improved more
open design
in the housing and rectifier to allow for more air flow and a cooler running,
more durable alternator.

Claims

4
CLAIMS
The embodiments of the invention in which an exclusive property or privilege
is claimed are defined as
follows:
1. An improved "10SI" alternator housing (Fig. 3 & 4) designed to be used in
conjunction with a larger
heavy duty improved "17SI' rectifier (Fig. 2) so that the resulting sub-
assembly is pictured in figures 5
and 6.
2. In reference to claim 1, the housing in figures 3 and 4.
3. In reference to claims land 2, the small notches (3A) in the housing figure
3 allow for added clearance
for the larger rectifier heat sink (2A) in fignre 2.
4. In reference to claims land 2, the extrusions (3B) in the housing figure 3
allow for the proper
grounding of the larger rectifier negative heat sink (2D) in figure 2.
5. In reference to claim 1, the rectifier pictured in figure 2.
6. In reference to claims 1 and 5, the increased number of diodes to 9 (2C) in
the rectifier figure 2 into the
"10SI" style housing in figure 3.
7. In reference to claims 1 and 5, the air flow paths (2B) in figure 2 of the
"17SI" style rectifier.
8. In reference to claims 1 and 2, the increased openings in the housing (6B)
in figure 6 for added air
flow.
9. In reference to claim 1, the housing pictured from the inside and back view
in various stages as evident
in figure 3, figure 4, figure 5 and figure 6.

Description

CA 02238773 1998-07-06
SPECIFICATIONS
This invention relates to an improved alternator housing to allow for the
installation of a larger enhanced,
heavy duty rectifier and for better cooling and reliability.
It is common in high output small frame alternators to have a high rate of
failure due to hotter
temperatures developed in small frame alternators caused by, increased
continuous high output charging
capability, lack of heat dissipation through undersized rectifier heat sinks
and diodes, insufficient cooling
(air exchange/air flow) through alternator and components, and the plugging up
of alternator by foreign
matter such as chaff & dust, further limiting the cooling capabilities of the
alternator.
We have found that the above factors contributing to early alternator failure
can be overcome or
significantly reduced. By redesigning the housing to allow for a larger
rectifier with larger heat sinks (and
thus its exposed surface area) and 9 50amp diodes versus the original 6 25amp
diodes (and thus
increasing its current carrying capability) as well as an improved more open
design in the housing and
rectifier to allow for more air flow and a cooler running, more durable
alternator.
In pictures which illustrate embodiments of the invention, Figurelis the front
and back view of the old
original rectifier, Figure 2 is the front and back view of the larger improved
heavy duty rectifier, Figure 3
is the inside view of the redesigned housing and Figure 4 is the back view of
the redesigned housing to
allow for the larger improved rectifier, Figure 5 is the inside view of the
housing with the rectifier
installed and Figure 6 is the back view of the housing with the rectifier
installed as an alternator sub
assembly.
The rectifiers illustrated, figure 1 the original rectifier, and figure 2 the
larger improved rectifier clearly
show the larger heat sinks (2A) as well as 3 new air flow paths (2B) for
better cooling. In addition the new
rectifier has 9 50 Amp diodes (2C) (6 positive & 3 negative diodes), versus
the original 6 25Amp diodes
(3 positive & 3 negative diodes), for increased current handling capability. A
cooler diode/rectifier
assembly results in significantly increased durability.
The sub-assembly pictured, Figure 5 illustrates the new improved rectifier
installed in the new housing.
Note notches (5A) in the housing to allow clearance for the larger rectifier.
The sub-assembly pictured, Figure 6 illustrates the new housing from the back
view with the new heavy
duty rectifier. Note the location of the thru bolts (6A) to fasten the new
rectifier. Also note the added
openings (6B) in the housing for extra ventilation.