Bridge rectifier module

Abstract

The utility model relates to the technical field of rectifiers, in particular to a bridge rectifier module, which comprises a bottom plate (1), a rectifying mechanism (2) is welded and fixed at the upper end of the bottom plate (1), and a shell (3) which is used for protecting the rectifying mechanism (2) together with the bottom plate (1) is arranged on the outer side of the rectifying mechanism (2) in a covering manner. The novel rectifier bridge module structure design and the injection molding production technology are adopted, the usage amount of raw materials is greatly reduced, resources are saved, the alternating current electrode is directly connected with the negative electrode of the chip, and the over-current capability is improved; injection molding is directly completed at a time after the support is welded, the production period and efficiency are greatly improved, the process period is shortened, energy is saved, and energy consumption is reduced.

Description

Technical Field

[0001] The utility model relates to the technical field of rectifiers, in particular to a bridge rectifier module. Background Art

[0002] Rectifier modules operate based on the unidirectional conduction principle of diodes. Generally speaking, diodes conduct in the forward direction and block in the reverse direction. In other words, a diode only allows current to flow in through the anode and out through the cathode. Therefore, when connected to an AC circuit, it rectifies the current into DC. A bridge rectifier consists of several (two, four, or six) rectifier diodes sealed together. Its primary function is to convert AC into DC. Rectifier modules come in three-phase, single-phase, full-bridge, and half-bridge configurations.

[0003] The common welded rectifier module packaging structure mainly includes busbar electrodes, chips, solder layers, lining plates, and substrates. The connection technology between these parts constitutes the key technology of rectifier module packaging, which can be divided into two aspects: chip welding and fixation, and interconnection and lead-out of each chip electrode. To improve the reliability of the module, it is required that the thermal expansion coefficient (CTE) of each component material matches, heat dissipation characteristics are good, and the connection interface is minimized and the connection is strong. The common existing welding processes include the following:

[0004] The traditional wafer welding packaging process: chip oxide layer removal - solder paste coating - electrode chip placement - tunnel sintering (mostly electric furnace welding) - cleaning rosin residue - semi-finished product testing - press-fit shell - silicone gel filling - epoxy resin filling - final testing - storage; the existing process requires three steps - press-fit shell - silicone gel filling - epoxy resin filling, and the time is three days.

[0005] Ordinary GPP chip welding process: structural parts preparation --- solid crystal --- adding molybdenum sheet --- vacuum eutectic --- void detection --- secondary welding (electrode) --- press-fit shell --- filling with silicone gel --- final test --- storage.

[0006] Shiling Electronics' welding process: structural parts preparation --- solid crystal --- vacuum eutectic --- void inspection --- aluminum wire bonding --- secondary welding (electrode) --- press-fit shell --- silicone gel filling --- final test --- storage.

[0007] Existing welding and packaging processes involve numerous production steps and consume significant energy. Furthermore, electrodes are typically made from a single piece of material, requiring significant material consumption. This multifaceted and complex production process also results in long production cycles and low efficiency. Therefore, those skilled in the art have proposed a production process for a bridge rectifier module to address the issues raised in the background art. Utility Model Content

[0008] In order to solve the above technical problems, the utility model provides a bridge rectifier module, including a base plate, a rectifier mechanism is welded and fixed to the upper end of the base plate, and an outer cover of the rectifier mechanism is provided with a shell that together with the base plate forms a protective shell for the rectifier mechanism.

[0009] Preferably, a through hole is provided on the left side of the bottom plate, and a U-shaped groove is provided on the right side.

[0010] Preferably, a plurality of pads are provided on the upper end of the bottom plate, and the pads are horizontally and evenly spaced on the upper surface of the bottom plate, and the bottom plate is fixed to the rectifier mechanism by welding through the pads.

[0011] Preferably: the rectifier mechanism is made of copper, and includes a plurality of electrode sheets 1, the number of which corresponds to the number of pads, and the electrode sheet 1 is configured to be L-shaped, with its bottom welded and fixed on the pad.

[0012] Preferably: two power bridges are provided on the upper end of the electrode sheet 1, and the two power bridges are distributed front and back, each power bridge is connected to the electrode sheet 1, and a protective ring is provided at the connection between the power bridge and the electrode sheet 1, and the protective ring is made of silicone ring.

[0013] Preferably, an electrode sheet 2 is provided on one side of the two power bridges adjacent to each other, and the two electrode sheets 2 are arranged diagonally, one end of the electrode sheet 2 is connected to the power bridge, and the other end is connected to the lower side of the electrode sheet 1 through a support foot.

[0014] Preferably, the housing is made of plastic, is formed by injection molding, and covers the outside of the rectification mechanism.

[0015] Preferably, side grooves are provided on both the left and right sides of the shell.

[0016] The technical effects and advantages of this utility model are:

[0017] The utility model adopts a new rectifier bridge module structure design and an injection molding structure, which greatly reduces the use of raw materials and saves resources. The AC electrode is directly connected to the negative electrode of the chip, which improves the overcurrent capacity. After the bracket is welded, the injection molding is completed in one go, which greatly improves the production cycle and efficiency, shortens the process cycle, saves energy, and reduces energy consumption. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] Figure 1 It is a structural diagram of the utility model;

[0019] Figure 2 It is a top view of the utility model;

[0020] Figure 3 It is a partial exploded schematic diagram of the utility model;

[0021] Figure 4 It is a structural diagram of the rectifier mechanism in the utility model.

[0022] In the picture:

[0023] 1. Bottom plate; 11. Through hole; 12. U-shaped groove; 13. Solder pad; 2. Rectification mechanism; 21. Electrode piece 1; 22. Power bridge; 23. Electrode piece 2; 24. Support foot; 25. Protective ring; 3. Housing; 31. Side groove. DETAILED DESCRIPTION

[0024] The present invention will be described in further detail below with reference to the accompanying drawings and specific embodiments. The embodiments of the present invention are provided for purposes of illustration and description and are not intended to be exhaustive or to limit the present invention to the disclosed forms. Many modifications and variations will be apparent to those skilled in the art. The embodiments are selected and described to better illustrate the principles and practical applications of the present invention and to enable those skilled in the art to understand the present invention and design various embodiments with various modifications suitable for specific applications.

[0025] Example 1

[0026] See also Figures 1 to 4 In this embodiment, a bridge rectifier module is provided, comprising a base plate 1, a rectifier mechanism 2 being provided at the upper end of the base plate 1, the two being welded and fixed therebetween, a housing 3 being provided on the outer side of the rectifier mechanism 2, the housing 3 and the base plate 1 enclosing and covering the rectifier mechanism 2, thereby protecting the rectifier circuit and preventing it from being affected by external electrical components during use;

[0027] Among them, a through hole 11 is opened on the left side of the bottom plate 1, and a U-shaped groove 12 is set on the right side. In addition, a plurality of welding pads 13 are provided on the upper end of the bottom plate 1. The welding pads 13 are evenly spaced laterally on the upper surface of the bottom plate 1. In this application, there are three welding pads 13, and the bottom plate 1 is welded and fixed to the rectifier mechanism 2 through the welding pads 13;

[0028] The rectifier mechanism 2 is made of copper with good heat dissipation and good electrical conductivity. In the rectifier mechanism 2, a plurality of electrode sheets 21 are included. The number of electrode sheets 21 corresponds to the number of pads 13. The electrode sheet 21 is set to an L shape, and its bottom is welded and fixed on the pad 13, thereby forming a form in which a plurality of electrode sheets 21 are horizontally distributed on the upper surface of the bottom plate 1. In this application, there are three electrode sheets 21, which correspond to the number of pads 13. At the same time, two power bridges 22 are provided on the upper end of the electrode sheet 21. , two power bridges 22 are distributed front and back, each power bridge 22 is connected to the electrode piece 1 21, and a protective ring 25 is provided at the connection between the power bridge 22 and the electrode piece 1 21. The protective ring 25 is made of silicone ring and plays a role in protecting the chip. The two power bridges 22 are each provided with an electrode piece 23 on the side close to each other. The two electrode pieces 23 are arranged diagonally. One end of the electrode piece 23 is connected to the power bridge 22, and the other end is connected to the lower side of the electrode piece 1 21 through the support foot 24 to achieve stable support for the electrode piece 23;

[0029] The shell 3 is made of plastic and is formed by injection molding. It covers the outside of the rectifier mechanism 2. Side grooves 31 are provided on both sides of the shell 3. The side grooves 31 are provided to avoid affecting the through hole 11 and the U-shaped groove 12 so that they can be used normally.

[0030] Example 2

[0031] In this embodiment, a production process for a bridge rectifier module is provided, which is specifically used to process the rectifier module in Example 1. The specific process steps are as follows:

[0032] 1) Structural component preparation: Prepare the structural components of the base plate 1 and the rectifier mechanism 2. The electrode sheet 1 21 and the electrode sheet 2 23 are both single-piece structures, different from the traditional one-piece structure. Furthermore, the electrode sheet 23 and the power bridge 22 are integrated into an integrated design, which facilitates welding, facilitates installation, and saves time.

[0033] 2) Welding assembly: The chip is welded to the electrode sheet 1 21 and the electrode sheet 2 23 through a die bonding and vacuum eutectic process. Since the existing technology is used, the specific process parameters and process are omitted here to form an integrated rectifier mechanism 2. The rectifier mechanism 2 is tested and then welded to the base plate 1 to complete the assembly. After assembly, it is tested again.

[0034] 3) Injection molding: The structural parts tested in step 2) are injection molded onto the outside of the rectifier mechanism 2 to form the housing 3. The injection molding process can be completed in one go, taking 5-6 hours. The injection molding process can also be automated, greatly saving time and improving efficiency. The process can now be done by one person instead of five. After the injection-molded rectifier module is tested, it can be stored in the warehouse.

[0035] The rectifier bridge module in the utility model adopts the above-mentioned production process. Since the electrodes are in a single-body form, more than 60% of copper materials are saved in the preparation of the electrodes. The entire internal structure is changed from the original No. 123 chip reversely connected to the positive electrode of the No. 456 chip to the AC electrode directly connected to the negative electrode of the chip, which improves the overcurrent capacity. After the bracket is welded, the injection molding is completed in one go, which greatly improves the production cycle and efficiency.

[0036] The utility model can greatly improve production efficiency and effectively reduce energy use, such as electricity costs, and solve the problem of traditional production processes with many steps and high energy consumption;

[0037] The utility model greatly reduces the use of materials, and the amount of copper used is greatly reduced. Compared with the traditional process, the amount of copper used is only 50% of the original;

[0038] The production process of the utility model is simple, and the original production cycle is reduced to two days, while the production cycle of the traditional process is about 6-7 days, thereby improving efficiency.

[0039] Obviously, the embodiments described are only some of the embodiments of the present invention, not all of them. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field and related fields without making any creative efforts should fall within the scope of protection of the present invention. Structures, devices, and operating methods not specifically described and explained in this utility model shall be implemented in accordance with conventional means in the field unless otherwise specified or limited.

Claims

1. A bridge rectifier module, characterized in that: The invention comprises a bottom plate (1), a rectifying mechanism (2) being welded and fixed to the upper end of the bottom plate (1), an outer cover of the rectifying mechanism (2) being provided with a shell (3) which, together with the bottom plate (1), has a protective effect on the rectifying mechanism (2), and the outer side of the rectifying mechanism (2) is formed by one-time injection molding to form the shell (3).

2. The bridge rectifier module according to claim 1, characterized in that: A through hole (11) is provided on the left side of the bottom plate (1), and a U-shaped groove (12) is provided on the right side.

3. The bridge rectifier module according to claim 2, characterized in that: A plurality of welding pads (13) are provided at the upper end of the bottom plate (1), and the welding pads (13) are distributed laterally at equal intervals on the upper surface of the bottom plate (1). The bottom plate (1) is fixed to the rectifier mechanism (2) by welding via the welding pads (13).

4. The bridge rectifier module according to claim 3, characterized in that: The rectifier mechanism (2) is made of copper. The rectifier mechanism (2) includes a plurality of electrode sheets (21). The number of electrode sheets (21) corresponds to the number of pads (13). The electrode sheets (21) are arranged in an L-shape, and their bottoms are welded and fixed on the pads (13).

5. The bridge rectifier module according to claim 4, characterized in that: Two power bridges (22) are provided at the upper end of the electrode sheet (21). The two power bridges (22) are distributed front to back. Each power bridge (22) is connected to the electrode sheet (21). A protective ring (25) is provided at the connection between the power bridge (22) and the electrode sheet (21). The protective ring (25) is made of a silicone ring.

6. The bridge rectifier module according to claim 5, characterized in that: Electrode sheet 2 (23) is provided on the adjacent side of the two power bridges (22), and the two electrode sheets 2 (23) are arranged diagonally. One end of electrode sheet 2 (23) is connected to the power bridge (22), and the other end is connected to the lower side of electrode sheet 1 (21) through a support leg (24).

7. The bridge rectifier module according to claim 1, characterized in that: The housing (3) is made of plastic material, is formed by an injection molding process, and covers the outside of the rectification mechanism (2).

8. The bridge rectifier module according to claim 7, characterized in that: Side grooves (31) are provided on both the left and right sides of the housing (3).

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