Alternator Diode Bridge Rectifier Platforms For Car And Truck Electrical Systems

Lisle, Ill. – Tricon Industries, Inc., has begun production of a robust line of alternator diode bridge rectifier platforms for use in passenger car and truck electrical systems. These insert molded subassemblies feature large stamped copper circuit paths, instead of conventional bus wiring, to provide termination surfaces for each diode lead.

"This type of rectifying diode assembly changes the electrical current produced by the vehicle alternator from alternating current (AC) to direct current (DC).," explains Rick Zech, Sales Manager, Tricon Industries. "The diodes are mounted on a heat sink plate in close proximity to the alternator where temperature and vibration are high. This is a pretty demanding environment calling for a component that can withstand high heat, carry high current and be securely mounted." Polyphenylene sulfide (PPS) plastic, with a high temperature rating, provides an acceptable insulator material for the platform body.

"By insert molding thick, stamped copper circuits into the platform body just above the diodes, we were able to eliminate the bus wiring commonly found in this type of component," says Rick Zech, Sales Manager, Tricon Industries. "Crimp terminals on the circuit paths are connected to the diode leads providing a robust, secure electrical connection that can handle high currents."

Registration between the cluster of diode leads, regulator leads and embedded mounting posts requires precise dimensional control of the metal components during the molding process. Tricon achieves this by using precision stampings and molds. Insert molding controls the location of metal parts and produces highly uniform subassemblies that consistently mate with other components.

"Tricon Industries produces several versions of these diode circuit platforms that mount on vehicle alternators," says Mr. Zech. "One version has a single layer circuit stamping insert molded into the plastic platform. This stamping is then separated into individual circuits by trimming through openings in the molded platform. Another version uses four separate circuit stampings that are insert molded at three different levels within the platform thickness."

"Before shipping, we perform hi-pot and continuity tests on all of the alternator diode bridge rectifier platforms," says Mr. Zech. "Each tested part is individually packaged within the shipping carton to prevent distortion of the protruding circuit terminals." These circuit platforms are shipped to customers in North America and in Europe.

Tricon Industries, Inc. is a QS-9000/ISO 9001 registered manufacturer specializing in insert molding and specialized components for worldwide automotive, mobile communications and appliance markets. Manufacture of parts like this circuit platform for high temperature, high current applications is considered a "core" business for Tricon. Some of Tricon's recent projects include complex insert molded junction blocks and multifunction switch components, sealed tail light bulbs and circuit stampings, single bulb light sockets, mobile antenna assemblies and wire terminations to circuit components. Today, Tricon provides comprehensive design, project management and manufacturing capabilities that can be customized to meet specific project requirements. Expanded capacity allows Tricon to serve customer needs to insure customer satisfaction and form lasting partnerships with their customers.